Surface cleaning apparatus

ABSTRACT

A surface cleaning apparatus comprises an air flow passage extending from a dirty air inlet to a clean air outlet and a suction motor. The surface cleaning apparatus may also comprise a cyclone chamber provided in the air flow passage. The cyclone chamber may comprise a cyclone air inlet, a cyclone air outlet and a dirt outlet. The surface cleaning apparatus may comprise a dirt collection chamber having a dirt inlet, a dirt collection chamber first end, an opposed dirt collection chamber second end and a longitudinally extending sidewall. Various design improvements are provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of 35 USC 371 based on theco-pending international application No. PCT/CA2012/000182, filed Mar.2, 2012, which itself claims the benefit of 35 USC 119 based on thepriority of co-pending U.S. patent application Ser. No. 13/040,711 filedMar. 4, 2011, U.S. patent application Ser. No. 13/040,955 filed Mar. 4,2011, U.S. patent application Ser. No. 13/040,751 filed Mar. 4, 2011,U.S. patent application Ser. No. 13/040,768 filed Mar. 4, 2011, U.S.patent application Ser. No. 13/040,731 filed Mar. 4, 2011, and U.S.patent application Ser. No. 13/040,934 filed Mar. 4, 2011, and each ofthose applications being incorporated herein in their entirety byreference.

FIELD

The disclosure relates to surface cleaning apparatuses, such as vacuumcleaners.

INTRODUCTION

Various constructions for surface cleaning apparatuses, such as vacuumcleaners, are known. Currently, many surface cleaning apparatuses areconstructed using at least one cyclonic cleaning stage. Air is drawninto the vacuum cleaners through a dirty air inlet and conveyed to acyclone inlet. The rotation of the air in the cyclone results in some ofthe particulate matter in the airflow stream being disentrained from theairflow stream. This material is then collected in a dirt bin collectionchamber, which may be at the bottom of the cyclone or in a directcollection chamber exterior to the cyclone chamber (see for exampleWO2009/026709 and U.S. Pat. No. 5,078,761). One or more additionalcyclonic cleaning stages and/or filters may be positioned downstreamfrom the cyclone.

SUMMARY

The following summary is provided to introduce the reader to the moredetailed discussion to follow. The summary is not intended to limit ordefine the claims.

According to one broad aspect of the teachings described herein, a dirtcollection chamber for one or more cyclone chambers extends from a dirtinlet towards a dirt collection area. For example, the dirt inlet may bein an upper portion of the dirt collection chamber and the dirtcollection area may be the floor of the dirt collection chamber. Thedirt collection chamber comprises a sidewall (preferably an outersidewall) that extends longitudinally between opposing first and secondends of the dirt collection chamber. Air circulating within the dirtcollection chamber may flow along the sidewall. For example, air mayexit the dirt outlet of the cyclone chamber and rotate around the dirtcollection chamber and travel towards the dirt collection area. The airwill at some point travel in the reverse direction towards the dirtinlet and re-enter the cyclone chamber. The dirt collection chamber maybe configured such that the cross sectional area of the dirt collectionchamber in a plane transverse to its length changes at least once alongthe length of the dirt collection chamber. In some embodiments, thecross-sectional area at the first end of the dirt collection chamber isdifferent than the cross-sectional area at the second end of the dirtcollection chamber.

An advantage of this configuration may be that changes in thecross-sectional area may be used to enhance the separation efficiency ofthe cyclone chamber and associated dirt collection chamber. By varyingthe transverse cross sectional area of the dirt collection chamber, theflow dynamics of the air in the dirt collection chamber may be variedand the amount of dirt that is disentrained from the air may bedecreased, or the amount of dirt that is re-entrained may be reduced.For example, if the cross sectional area of the portion of the dirtcollection chamber distal to the dirt inlet (e.g., the lower portion) isless than the opposed portion (e.g. upper portion) adjacent the dirtinlet, then the air will slow down as it enters the upper portion. Asthe velocity decreases, the amount of dirt that may be re-entrained inthe return airflow may decrease. If the cross sectional area of theportion of the dirt collection chamber distal to the dirt inlet (e.g.,the lower portion) is greater than the opposed portion (e.g. upperportion) adjacent the dirt inlet, then the air will slow down as itenters the lower portion allowing more dirt to be disentrained.

The cyclone chamber and dirt collection chamber assembly may be used inany surface cleaning apparatus. The surface cleaning apparatus comprisesan air flow passage extending from a dirty air inlet to a clean airoutlet. A suction motor is provided in the air flow passage, and acyclone bin assembly is provided in the air flow passage, preferablyupstream from the suction motor. The cyclone bin assembly may comprisethe cyclone chamber and a dirt collection chamber. Dirty air from thedirty air inlet may circulate within the cyclone chamber and may exitthe cyclone chamber to circulate within the dirt collection chamber.

The cyclone bin assembly may also comprise a fine particle separator, tohelp separate relatively fine dirt particles from the dirty air. Thefine particle separator comprises a flow chamber through which the dirtyair may circulate. Dirty air, carrying entrained fine dirt particles mayflow from the cyclone chamber into the fine particle separator. Airexiting the fine particle separator may re-enter the cyclone chamber,and travel to the suction motor via a cyclone air outlet.

The fine particle separator is configured so that air circulating in theflow chamber may travel at a relatively high velocity, and may travelfaster than the air circulating within the cyclone chamber. To helpincrease the air flow velocity the cross-sectional area of the flowchamber, in the flow direction, may be varied, and preferably isreduced. Accelerating the dirty air to a relatively higher velocity mayhelp disentrain fine dirt particles.

The air outlet of the fine particle separator flow chamber may beconfigured to disrupt the flow of air exiting the flow chamber.Disrupting the flow of air, for example by introducing eddy currentsand/or turbulence and/or directing the air away from the cyclone dirtoutlet, may help separate fine dirt particles from the air stream.Separated dirt particles may fall into the dirt collection chamber.

An advantage of this configuration may be a more efficient separation offine dirt particles from the dirty air stream. Separating fine dirtparticles from the dirty air stream in the fine particle separator mayhelp prevent the fine dirt particles from continuing downstream from thecyclone bin assembly, and, for example, fouling the suction motor and/ora pre-motor filter.

In accordance with this aspect a surface cleaning apparatus comprises anair flow passage extending from a dirty air inlet to a clean air outlet.The air flow passage includes a suction motor. The surface cleaningapparatus may also comprise a cyclone chamber provided in the air flowpassage. The cyclone chamber may comprise a cyclone air inlet, a cycloneair outlet and a dirt outlet. The surface cleaning apparatus maycomprise a dirt collection chamber having a dirt inlet, a dirtcollection chamber first end, an opposed dirt collection chamber secondend and a longitudinally extending sidewall. The sidewall may comprise aportion that has a longitudinal length and extends away from the dirtinlet towards the opposed dirt collection chamber second end. Atransverse cross sectional area of the dirt collection chamber may varyat least once along the length of the portion of the sidewall.

The dirt inlet may be positioned adjacent the dirt collection chamberfirst end.

A dirt collection area may be provided at the opposed dirt collectionchamber second end.

The dirt collection chamber first end may be an upper end. The dirtinlet may be provided at the upper end, and a dirt collection area maybe provided in a lower portion of the dirt collection chamber.

The dirt collection chamber may be exterior to the cyclone chamber.

The dirt collection chamber may surround at least a portion of thecyclone chamber.

The dirt collection chamber may surround the cyclone chamber.

The cyclone chamber and the dirt collection chamber may be provided in acyclone bin assembly. The cyclone bin assembly may be removably mountedto the surface cleaning apparatus.

The portion of the sidewall may include at least one discontinuity.

The portion of the sidewall may extend inwardly at a position along itslength whereby the transverse cross sectional area may be reduced.

The portion of the sidewall may extend inwardly at a position along itslength whereby the transverse cross sectional area may be increased.

The dirt collection chamber may surround at least a portion of thecyclone chamber. The dirt collection chamber may have an inner sideadjacent the cyclone chamber and an outer side spaced from the cyclonechamber. The portion of the sidewall may be provided at the outer side.

The portion of the sidewall may include at least one discontinuity.

The portion of the sidewall may extend inwardly at a position along itslength whereby the transverse cross sectional area may be reduced.

The portion of the sidewall may extend inwardly at a position along itslength whereby the transverse cross sectional area may be increased.

The cyclone air inlet may be at a first end of the cyclone chamber. Thedirt outlet may be provided at a second opposed end of the cyclonechamber.

The dirt inlet may be at an upper end of the cyclone chamber.

The surface cleaning apparatus may comprise a rib extending between theinner side and the outer side. The rib may be provided along the portionof the sidewall.

The rib may extend only part way along the portion of the sidewall.

According to another broad aspect of the teachings described herein, asurface cleaning apparatus comprises a cyclone chamber and a fineparticle separator in flow communication with the cyclone chamber viathe cyclone chamber dirt outlet. The fine particle separator helps toseparate relatively fine dirt particles from the dirty air. The fineparticle separator comprises a flow chamber through which the dirty airmay circulate. Dirty air, carrying entrained fine dirt particles mayflow from the cyclone chamber into the fine particle separator. Airexiting the fine particle separator may re-enter the cyclone chamber,and travel to the suction motor via a cyclone air outlet.

The fine particle separator is configured so that air circulating in theflow chamber may travel at a relatively high velocity, and may travelfaster than the air circulating within the cyclone chamber to therebyseparate finer dirt particles than those separated in the cyclonechamber. To help increase the air flow velocity, the cross-sectionalarea of the flow chamber, in the flow direction, may be varied, andpreferably is reduced. Accelerating the dirty air to a relatively highervelocity may help disentrain fine dirt particles.

The air outlet of the fine particle separator flow chamber may beconfigured to disrupt the flow of air exiting the flow chamber.Disrupting the flow of air, for example by introducing eddy currentsand/or turbulence and/or directing the air away from the cyclone dirtoutlet, may help separate fine dirt particles from the air stream.Separated dirt particles may fall into the dirt collection chamber.

An advantage of this configuration may be a more efficient separation offine dirt particles from the dirty air stream. Separating fine dirtparticles from the dirty air stream in the fine particle separator mayhelp prevent the fine dirt particles from continuing downstream from thecyclone bin assembly, and, for example, fouling the suction motor and/ora pre-motor filter.

The cyclone air outlet may be in communication with an exit duct conduit(which may be a down duct depending upon the orientation of the ductconduit) extending away from the cyclone air outlet and preferablythrough (e.g., linearly through) a dirt collection chamber having a wall(e.g., a floor) facing the end of the cyclone chamber with the airoutlet. For example, the down duct may extend from the floor of thecyclone chamber to the floor of the dirt collection chamber. Reinforcingribs may extend between the down duct and the floor of the cyclonechamber. The ribs may help reduce vibrations in the down duct and/or thefloor of the dirt collection chamber, including, for example, vibrationsinduced by air flowing through the down duct. Optionally, the down ductand/or the support ribs may be removable.

An advantage of this configuration may be that vibration of the downduct and/or the floor of the dirt collection chamber may be reduced.Reducing the vibration of the down duct and/or the floor of the dirtcollection chamber may help reduce the overall amount of noise generatedby the surface cleaning apparatus and/or improve the separationefficiency of the cyclone chamber and the dirt collection chamber.

The dirt collection chamber may extend from a dirt inlet towards a dirtcollection area. For example, the dirt inlet may be in an upper portionof the dirt collection chamber and the dirt collection area may be thefloor of the dirt collection chamber. The dirt collection chambercomprises a sidewall (preferably an outer sidewall) that extendslongitudinally between opposing first and second ends of the dirtcollection chamber. Air circulating within the dirt collection chambermay flow along the sidewall. For example, air may exit the dirt outletof the cyclone chamber and rotate around the dirt collection chamber andtravel towards the dirt collection area. The air will at some pointtravel in the reverse direction towards the dirt inlet and re-enter thecyclone chamber. The dirt collection chamber may be configured such thatthe cross sectional area of the dirt collection chamber in a planetransverse to its length changes at least once along the length of thedirt collection chamber. In some embodiments, the cross-sectional areaat the first end of the dirt collection chamber is different than thecross-sectional area at the second end of the dirt collection chamber.

An advantage of this configuration may be that changes in thecross-sectional area may be used to enhance the separation efficiency ofthe cyclone chamber and associated dirt collection chamber. By varyingthe transverse cross sectional area of the dirt collection chamber, theflow dynamics of the air in the dirt collection chamber may be variedand the amount of dirt that is disentrained from the air may bedecreased, or the amount of dirt that is re-entrained may be reduced.For example, if the cross sectional area of the portion of the dirtcollection chamber distal to the dirt inlet (e.g., the lower portion) isless than the opposed portion (e.g. upper portion) adjacent the dirtinlet, then the air will slow down as it enters the upper portion. Asthe velocity decreases, the amount of dirt that may be re-entrained inthe return airflow may decrease. If the cross sectional area of theportion of the dirt collection chamber distal to the dirt inlet (e.g.,the lower portion) is greater than the opposed portion (e.g. upperportion) adjacent the dirt inlet, then the air will slow down as itenters the lower portion allowing more dirt to be disentrained.

The cyclone chamber and dirt collection chamber assembly may be used inany surface cleaning apparatus. The surface cleaning apparatus comprisesan air flow passage extending from a dirty air inlet to a clean airoutlet. A suction motor is provided in the air flow passage, and acyclone bin assembly is provided in the air flow passage, preferablyupstream from the suction motor. The cyclone bin assembly may comprise acyclone chamber and a dirt collection chamber. Dirty air from the dirtyair inlet may circulate within the cyclone chamber and may exit thecyclone chamber to circulate within the dirt collection chamber.

In accordance with this aspect, a surface cleaning apparatus comprisesan air flow passage extending from a dirty air inlet to a clean airoutlet. The air flow passage includes a suction motor. The surfacecleaning apparatus may also comprise a cyclone chamber provided in theair flow passage. The cyclone chamber may comprise a cyclone air inlet,a cyclone air outlet, a dirt outlet and a cyclone chamber wall. Thesurface cleaning apparatus may also comprise a fine particle separator.The fine particle separator may comprise an annular flow channel, a fineparticle separator inlet in communication with the cyclone chamber viathe cyclone dirt outlet, a fine particle separator dirt outlet and afine particle separator sidewall. The surface cleaning apparatus mayalso comprise a dirt collection chamber in communication with the fineparticle separator dirt outlet. The dirt collection chamber may comprisea dirt collection chamber sidewall.

The fine particle separator may surround at least a portion of thecyclone chamber.

The fine particle separator inlet may comprise an inlet for air and fineparticles to enter the fine particle separator and an outlet for air tore-enter the cyclone chamber.

The fine particle separator inlet may be the sole communication betweenthe cyclone chamber and the fine particle separator.

The cyclone dirt outlet may comprise a slot that extends part way aroundthe cyclone chamber wall.

The slot may be provided adjacent a first end of the cyclone chamber.The cyclone air inlet may be provided at a second opposed end of thecyclone chamber.

The cyclone chamber air outlet may be provided at the second opposed endof the cyclone chamber.

The first end of the cyclone chamber may be an upper end of the cyclonechamber.

The fine particle separator may be positioned above the dirt collectionchamber.

The annular flow channel may have an axis of rotation and a crosssectional area in a plane parallel to the axis of rotation.

The cross sectional area may vary at at least one location in theannular flow channel.

The cross sectional area may decrease in a downstream direction.

The cross sectional area may decrease in a downstream portion of theannular flow channel towards the fine particle separator inlet.

A width and/or a height of the annular flow channel may be varied tovary the cross sectional area.

A downstream portion of the annular flow channel adjacent the fineparticle separator inlet may be configured to be spaced further radiallyoutwardly from the fine particle separator inlet than a portion of theannular flow channel upstream thereof.

The fine particle separator may have an inner wall. The inner wall maycomprise a ramp section adjacent the fine particle separator inlet whichextends radially outwardly and in a direction of rotation.

The fine particle separator may extend between the fine particleseparator sidewall and the cyclone chamber wall.

The fine particle separator may comprise an annular flow channel havinga closed end and an opposed open end that may comprise the fine particleseparator dirt outlet. The dirt collection chamber may extend away fromthe fine particle separator dirt outlet.

The fine particle separator may comprise an annular flow channel havingan upper end and an open lower end that may comprise the fine particleseparator dirt outlet and the dirt collection chamber extends away fromthe fine particle separator dirt outlet and surrounds at least a portionof the cyclone chamber.

The dirt collection chamber may comprise an annular region extendingaround the cyclone chamber.

The surface cleaning apparatus may comprise a rib provided in the dirtcollection chamber. The rib may extend between the dirt collectionchamber sidewall and a radially inner wall of the dirt collectionchamber.

The rib may extend only part way along the radially inner wall.

The dirt collection chamber sidewall may comprise an extension of thefine particle separator sidewall and the radially inner wall maycomprise a portion of the cyclone chamber wall.

The dirt collection chamber sidewall may comprise an extension of thefine particle separator sidewall.

The dirt collection chamber sidewall may comprise a discontinuity alongits length.

According to another broad aspect of the teachings described herein, adirt collection chamber for one or more cyclone chambers extends from adirt inlet towards a dirt collection area. For example, the dirt inletmay be in an upper portion of the dirt collection chamber and the dirtcollection area may be the floor of the dirt collection chamber. Thedirt collection chamber comprises an annular flow region with atransverse rib or baffle extending part way and, preferably, the entirewidth of the dirt collection chamber between the inner and outersidewalls of the annular flow region (e.g., the rib may extend betweenan outer surface of the cyclone chamber and an opposing inner surface ofthe surrounding dirt collection chamber). A portion of the dirty aircirculating within the cyclone chamber may exit the cyclone chamber viathe dirt outlet and circulate within the surrounding dirt collectionchamber. Preferably, the rib is adjacent the dirt outlet of the cyclonechamber. More preferably, the rib is positioned between the dirt outletand a discontinuity in the dirt collection chamber sidewall. The rib mayextend part way along the length of the annular dirt collection region.

An advantage of this configuration may be that dirty air circulatingwithin the dirt collection chamber may be disrupted by the rib, whichmay help disentrain dirt particles from the dirty air stream. Anotheradvantage of this design is that rotational flow of air in the dirtcollection chamber may be reduced or stopped thereby reducing there-entrainment of separated particulate material.

The dirt collection chamber may comprise a sidewall (preferably an outersidewall) that extends longitudinally between opposing first and secondends of the dirt collection chamber. Air that may be circulating withinthe dirt collection chamber may flow along the sidewall. For example,air may exit the dirt outlet of the cyclone chamber and rotate aroundthe dirt collection chamber and travel towards the dirt collection area.The air will at some point travel in the reverse direction towards thedirt inlet and re-enter the cyclone chamber. The dirt collection chambermay be configured such that the cross sectional area of the dirtcollection chamber in a plane transverse to its length changes at leastonce along the length of the dirt collection chamber. In someembodiments, the cross-sectional area at the first end of the dirtcollection chamber is different than the cross-sectional area at thesecond end of the dirt collection chamber.

An advantage of this configuration may be that changes in thecross-sectional area may be used to enhance the separation efficiency ofthe cyclone chamber and associated dirt collection chamber. By varyingthe transverse cross sectional area of the dirt collection chamber, theflow dynamics of the air in the dirt collection chamber may be variedand the amount of dirt that is disentrained from the air may bedecreased, or the amount of dirt that is re-entrained may be reduced.For example, if the cross sectional area of the portion of the dirtcollection chamber distal to the dirt inlet (e.g., the lower portion) isless than the opposed portion (e.g. upper portion) adjacent the dirtinlet, then the air will slow down as it enters the upper portion. Asthe velocity decreases, the amount of dirt that may be re-entrained inthe return airflow may decrease. If the cross sectional area of theportion of the dirt collection chamber distal to the dirt inlet (e.g.,the lower portion) is greater than the opposed portion (e.g. upperportion) adjacent the dirt inlet, then the air will slow down as itenters the lower portion allowing more dirt to be disentrained.

The cyclone chamber and dirt collection chamber assembly may be used inany surface cleaning apparatus. The surface cleaning apparatus comprisesan air flow passage extending from a dirty air inlet to a clean airoutlet. A suction motor is provided in the air flow passage, and acyclone bin assembly is provided in the air flow passage, preferablyupstream from the suction motor. The cyclone bin assembly may comprisethe cyclone chamber and a dirt collection chamber. Dirty air from thedirty air inlet may circulate within the cyclone chamber and may exitthe cyclone chamber to circulate within the dirt collection chamber.

The cyclone bin assembly may also comprise a fine particle separator, tohelp separate relatively fine dirt particles from the dirty air. Thefine particle separator may comprise a flow chamber through which thedirty air may circulate. Dirty air, carrying entrained fine dirtparticles may flow from the cyclone chamber into the fine particleseparator. Air exiting the fine particle separator may re-enter thecyclone chamber, and travel to the suction motor via a cyclone airoutlet.

The fine particle separator may be configured so that air circulating inthe flow chamber may travel at a relatively high velocity, and maytravel faster than the air circulating within the cyclone chamber. Tohelp increase the air flow velocity, the cross-sectional area of theflow chamber, in the flow direction, may be varied, and preferably isreduced. Accelerating the dirty air to a relatively higher velocity mayhelp disentrain fine dirt particles.

The air outlet of the fine particle separator flow chamber may beconfigured to disrupt the flow of air exiting the flow chamber.Disrupting the flow of air, for example by introducing eddy currentsand/or turbulence and/or directing the air away from the cyclone dirtoutlet, may help separate fine dirt particles from the air stream.Separated dirt particles may fall into the dirt collection chamber.

An advantage of this configuration may be a more efficient separation offine dirt particles from the dirty air stream. Separating fine dirtparticles from the dirty air stream in the fine particle separator mayhelp prevent the fine dirt particles from continuing downstream from thecyclone bin assembly, and, for example, fouling the suction motor and/ora pre-motor filter.

In accordance with this aspect, a surface cleaning apparatus maycomprise an air flow passage extending from a dirty air inlet to a cleanair outlet. The air flow passage includes a suction motor. The surfacecleaning apparatus may also comprise a cyclone chamber in the air flowpassage. The cyclone chamber may comprise a cyclone air inlet, a cycloneair outlet, a cyclone dirt outlet and a cyclone chamber wall. Thesurface cleaning apparatus may also comprise a dirt collection chamberhaving a dirt inlet in communication with the cyclone dirt outlet. Atleast a portion of the cyclone chamber may be in the dirt collectionchamber. The dirt collection chamber may comprise an inner side adjacentthe cyclone chamber and an outer side spaced from the cyclone chamberand defined by a dirt collection chamber sidewall. A rib may extendbetween the inner side and the outer side.

The rib extends only part way along the inner side.

The dirt collection chamber may have a first end and a second opposedend. The dirt inlet may be provided at the first end and the rib may bespaced from the dirt inlet towards the second opposed end.

The dirt inlet may be positioned adjacent a first end of the dirtcollection chamber.

The dirt collection chamber may comprise a dirt collection area that isprovided at a second end opposed to the first end.

The dirt inlet may be at an upper end of the dirt collection chamber andthe dirt collection area may be in a lower portion of the dirtcollection chamber.

The dirt collection chamber may surround the cyclone chamber.

The dirt collection chamber may extend part way around the cyclonechamber to define a sector. The rib may be provided at a location spacedfrom each end of the sector.

The cyclone chamber and the dirt collection chamber may be provided in acyclone bin assembly. The cyclone bin assembly may be removably mountedto the surface cleaning apparatus.

The dirt collection chamber sidewall may include at least onediscontinuity.

The dirt collection chamber may have a first end and a second opposedend. The dirt inlet may be provided at the first end and the rib may bespaced from the dirt inlet towards the second opposed end.

The rib may be provided between the cyclone dirt outlet and thediscontinuity.

A portion of the dirt collection chamber sidewall may extend inwardly ata position along its length.

A portion of the dirt collection chamber sidewall may extend outwardlyat a position along its length

The cyclone dirt outlet may comprise a slot that extends part way aroundthe cyclone chamber wall.

The slot may be provided adjacent a first end of the cyclone chamber andthe cyclone air inlet may be provided at a second opposed end of thecyclone chamber.

The cyclone chamber air outlet may be provided at the second opposed endof the cyclone chamber.

The first end of the cyclone chamber may be an upper end of the cyclonechamber.

The surface cleaning apparatus may comprise an annular flow chamberexterior to the cyclone chamber. The annular flow chamber may have afirst end and a second end spaced from the first end and incommunication with the dirt collection chamber.

The annular flow chamber may comprise a volume contiguous with the dirtcollection chamber and located between the first end of the annular flowchamber and the rib.

The rib may have an end facing the first end. The end may be spaced fromthe first end of the annular flow chamber.

The cyclone dirt outlet may be the dirt collection chamber dirt inlet.

According to yet another broad aspect of the teachings described herein,a cyclone bin assembly comprises a cyclone chamber and a dirt collectionchamber. The cyclone air outlet is in communication with an exit ductconduit (which may be a down duct depending upon the orientation of theduct conduit) extending away from the cyclone air outlet and preferablythrough (e.g., linearly through) a dirt collection chamber having a wall(e.g., a floor) facing the end of the cyclone chamber with the airoutlet. The down duct may extend from the floor of the cyclone chamberto the floor of the dirt collection chamber. Reinforcing ribs may beprovided and may extend between the down duct and the floor of thecyclone chamber. The ribs may help reduce vibrations in the down ductand/or the floor of the dirt collection chamber, including, for example,vibrations induced by air flowing through the down duct. Optionally, thedown duct and/or the support ribs may be removable.

An advantage of this configuration may be that vibration of the downduct and/or the floor of the dirt collection chamber may be reduced.Reducing the vibration of the down duct and/or the floor of the dirtcollection chamber may help reduce the overall amount of noise generatedby the surface cleaning apparatus and/or improve the separationefficiency of the cyclone chamber and the dirt collection chamber.

The dirt collection chamber may extend from a dirt inlet towards a dirtcollection area. For example, the dirt inlet may be in an upper portionof the dirt collection chamber and the dirt collection area may be thefloor of the dirt collection chamber. The dirt collection chambercomprises a sidewall (preferably an outer sidewall) that extendslongitudinally between opposing first and second ends of the dirtcollection chamber. Air circulating within the dirt collection chambermay flow along the sidewall. For example, air may exit the dirt outletof the cyclone chamber and rotate around the dirt collection chamber andtravel towards the dirt collection area. The air will at some pointtravel in the reverse direction towards the dirt inlet and re-enter thecyclone chamber. The dirt collection chamber may be configured such thatthe cross sectional area of the dirt collection chamber in a planetransverse to its length changes at least once along the length of thedirt collection chamber. In some embodiments, the cross-sectional areaat the first end of the dirt collection chamber is different than thecross-sectional area at the second end of the dirt collection chamber.

An advantage of this configuration may be that changes in thecross-sectional area may be used to enhance the separation efficiency ofthe cyclone chamber and associated dirt collection chamber. By varyingthe transverse cross sectional area of the dirt collection chamber, theflow dynamics of the air in the dirt collection chamber may be variedand the amount of dirt that is disentrained from the air may bedecreased, or the amount of dirt that is re-entrained may be reduced.For example, if the cross sectional area of the portion of the dirtcollection chamber distal to the dirt inlet (e.g., the lower portion) isless than the opposed portion (e.g. upper portion) adjacent the dirtinlet, then the air will slow down as it enters the upper portion. Asthe velocity decreases, the amount of dirt that may be re-entrained inthe return airflow may decrease. If the cross sectional area of theportion of the dirt collection chamber distal to the dirt inlet (e.g.,the lower portion) is greater than the opposed portion (e.g. upperportion) adjacent the dirt inlet, then the air will slow down as itenters the lower portion allowing more dirt to be disentrained.

The cyclone chamber and dirt collection chamber assembly may be used inany surface cleaning apparatus. The surface cleaning apparatus comprisesan air flow passage extending from a dirty air inlet to a clean airoutlet. A suction motor is provided in the air flow passage, and acyclone bin assembly is provided in the air flow passage, preferablyupstream from the suction motor. The cyclone bin assembly may comprisethe cyclone chamber and a dirt collection chamber. Dirty air from thedirty air inlet may circulate within the cyclone chamber and may exitthe cyclone chamber to circulate within the dirt collection chamber.

The cyclone bin assembly may also comprise a fine particle separator, tohelp separate relatively fine dirt particles from the dirty air. Thefine particle separator may comprise a flow chamber through which thedirty air may circulate. Dirty air, carrying entrained fine dirtparticles may flow from the cyclone chamber into the fine particleseparator. Air exiting the fine particle separator may re-enter thecyclone chamber, and travel to the suction motor via a cyclone airoutlet.

The fine particle separator is configured so that air circulating in theflow chamber may travel at a relatively high velocity, and may travelfaster than the air circulating within the cyclone chamber. To helpincrease the air flow velocity the cross-sectional area of the flowchamber, in the flow direction, may be varied, and preferably isreduced. Accelerating the dirty air to a relatively higher velocity mayhelp disentrain fine dirt particles.

The air outlet of the fine particle separator flow chamber may beconfigured to disrupt the flow of air exiting the flow chamber.Disrupting the flow of air, for example by introducing eddy currentsand/or turbulence and/or directing the air away from the cyclone dirtoutlet, may help separate fine dirt particles from the air stream.Separated dirt particles may fall into the dirt collection chamber.

An advantage of this configuration may be a more efficient separation offine dirt particles from the dirty air stream. Separating fine dirtparticles from the dirty air stream in the fine particle separator mayhelp prevent the fine dirt particles from continuing downstream from thecyclone bin assembly, and, for example, fouling the suction motor and/ora pre-motor filter.

In accordance with this aspect, a surface cleaning apparatus maycomprise an air flow passage extending from a dirty air inlet to a cleanair outlet and a suction motor. The surface cleaning apparatus maycomprise a cyclone chamber provided in the air flow passage. The cyclonechamber may comprise a cyclone chamber first end and a cyclone chambersecond opposed end, a cyclone air inlet, a cyclone air outlet providedat the cyclone chamber second opposed end and a cyclone chamber wall. Anair exit conduit may be exterior to the cyclone chamber and may extendfrom the cyclone air outlet. At least one reinforcing rib may bepositioned in abutting relationship with the air exit conduit and thecyclone chamber second opposed end.

The reinforcing rib may be connected to the air exit conduit.

The reinforcing rib may be connected to the cyclone chamber secondopposed end.

The air exit conduit may extend through a dirt collection chamber thatmay be positioned exterior to the cyclone chamber.

The air exit conduit may be removably mounted to the cyclone chamber.

The cyclone chamber may comprise a vortex finder and the vortex finderremains in position when the air exit conduit is removed.

The cyclone air inlet may be located adjacent the cyclone chamber secondopposed end.

The cyclone chamber may comprise a cyclone dirt outlet located adjacentthe cyclone chamber first end. The surface cleaning apparatus maycomprise a dirt collection chamber in communication with the cyclonedirt outlet.

The dirt collection chamber may extend at least part way around thecyclone chamber. The dirt collection chamber may have a dirt collectionchamber first end and a dirt collection chamber second opposed end thatmay be spaced from and may face the cyclone chamber second opposed end.The air exit conduit may extend between the cyclone chamber secondopposed end and the dirt collection chamber second opposed end.

The surface cleaning apparatus may comprise a cyclone bin assembly thatis removably mounted to the surface cleaning apparatus, the cyclone binassembly comprising the cyclone chamber and a dirt collection chamber.

The air exit conduit may extend through the dirt collection chamber.

The cyclone air outlet may be provided in the cyclone chamber secondopposed end. The dirt collection chamber may have a dirt collectionchamber end that is spaced from and faces the cyclone chamber secondopposed end. The air exit conduit may extend between the cyclone chambersecond opposed end and the dirt collection chamber end.

The dirt collection chamber end may be openable.

The dirt collection chamber end may have an air exit port incommunication with the air exit conduit and the air exit conduit remainsin position when the dirt collection chamber end is opened.

The air exit conduit may be removably mounted to the cyclone chamber.

The cyclone chamber may comprise a vortex finder and the vortex findermay remain in position when the air exit conduit is removed.

The cyclone air inlet may be located adjacent the cyclone chamber secondopposed end.

The cyclone chamber may comprise a cyclone dirt outlet located adjacentthe cyclone chamber first end. The surface cleaning apparatus maycomprise a dirt collection chamber in communication with the cyclonedirt outlet.

According to yet another broad aspect of the teachings described herein,a dirt collection chamber is provided with one or more recessed areas onthe outer sidewall of the dirt collection chamber. The dirt collectionchamber is separate from (e.g., exterior to) the cyclone chamber.Preferably, the recess is a longitudinally extending recess. The recessmay extend from the floor of the dirt collection chamber to the floor ofthe cyclone chamber, and may extend past the floor of the cyclonechamber. The recess provides a discontinuity on the inner surface of thedirt collection chamber sidewall. The discontinuity may disrupt the flowof the dirty air flowing along the inner surface of the sidewall, whichmay help disentrain dirt particles from the dirty airflow. The ejecteddirt particles may collect within the recess, and may fall to the floorof the dirt collection chamber if the recess extends to the floor. Therecess may also help inhibit re-entrainment of the ejected dirtparticles.

The leading or upstream side of the recess preferably forms a relativelysharp corner with the inner surface of the sidewall. The relativelysharp corner may increase the disruptions in the air flow.

An advantage of this configuration may be a more efficient separation ofdirt particles from the dirty air stream. Separating dirt particles fromthe dirty air stream in the dirt collection chamber may help prevent thefine dirt particles from continuing downstream from the cyclone binassembly, and, for example, fouling the suction motor and/or a pre-motorfilter.

A cyclone bin assembly may comprise a cyclone chamber and the dirtcollection chamber. The cyclone air outlet may be in communication withan exit duct conduit (which may be a down duct depending upon theorientation of the duct conduit) extending away from the cyclone airoutlet and preferably through (e.g., linearly through) a dirt collectionchamber facing the end of the cyclone chamber with the air outlet. Thedown duct may extend from the floor of the cyclone chamber to the floorof the dirt collection chamber. Reinforcing ribs may extend between thedown duct and the floor of the cyclone chamber. The ribs may help reducevibrations in the down duct and/or the floor of the dirt collectionchamber, including, for example, vibrations induced by air flowingthrough the down duct. Optionally, the down duct and/or the support ribsmay be removable.

An advantage of this configuration may be that vibration of the downduct and/or the floor of the dirt collection chamber may be reduced.Reducing the vibration of the down duct and/or the floor of the dirtcollection chamber may help reduce the overall amount of noise generatedby the surface cleaning apparatus and/or improve the separationefficiency of the cyclone chamber and the dirt collection chamber.

The dirt collection chamber may extend from a dirt inlet towards a dirtcollection area. For example, the dirt inlet may be in an upper portionof the dirt collection chamber and the dirt collection area may be thefloor of the dirt collection chamber. The dirt collection chambercomprises a sidewall (preferably an outer sidewall) that extendslongitudinally between opposing first and second ends of the dirtcollection chamber. Air circulating within the dirt collection chambermay flow along the sidewall. For example, air may exit the dirt outletof the cyclone chamber and rotate around the dirt collection chamber andtravel towards the dirt collection area. The air will at some pointtravel in the reverse direction towards the dirt inlet and re-enter thecyclone chamber. The dirt collection chamber may be configured such thatthe cross sectional area of the dirt collection chamber in a planetransverse to its length changes at least once along the length of thedirt collection chamber. In some embodiments, the cross-sectional areaat the first end of the dirt collection chamber is different than thecross-sectional area at the second end of the dirt collection chamber.

An advantage of this configuration may be that changes in thecross-sectional area may be used to enhance the separation efficiency ofthe cyclone chamber and associated dirt collection chamber. By varyingthe transverse cross sectional area of the dirt collection chamber, theflow dynamics of the air in the dirt collection chamber may be variedand the amount of dirt that is disentrained from the air may bedecreased, or the amount of dirt that is re-entrained may be reduced.For example, if the cross sectional area of the portion of the dirtcollection chamber distal to the dirt inlet (e.g., the lower portion) isless than the opposed portion (e.g. upper portion) adjacent the dirtinlet, then the air will slow down as it enters the upper portion. Asthe velocity decreases, the amount of dirt that may be re-entrained inthe return airflow may decrease. If the cross sectional area of theportion of the dirt collection chamber distal to the dirt inlet (e.g.,the lower portion) is greater than the opposed portion (e.g. upperportion) adjacent the dirt inlet, then the air will slow down as itenters the lower portion allowing more dirt to be disentrained.

The cyclone chamber and dirt collection chamber assembly may be used inany surface cleaning apparatus. The surface cleaning apparatus comprisesan air flow passage extending from a dirty air inlet to a clean airoutlet. A suction motor is provided in the air flow passage, and acyclone bin assembly is provided in the air flow passage, preferablyupstream from the suction motor. The cyclone bin assembly may comprisethe cyclone chamber and a dirt collection chamber. Dirty air from thedirty air inlet may circulate within the cyclone chamber and may exitthe cyclone chamber to circulate within the dirt collection chamber.

The cyclone bin assembly may also comprise a fine particle separator, tohelp separate relatively fine dirt particles from the dirty air. Thefine particle separator may comprise a flow chamber through which thedirty air may circulate. Dirty air, carrying entrained fine dirtparticles may flow from the cyclone chamber into the fine particleseparator. Air exiting the fine particle separator may re-enter thecyclone chamber, and travel to the suction motor via a cyclone airoutlet.

The fine particle separator is configured so that air circulating in theflow chamber may travel at a relatively high velocity, and may travelfaster than the air circulating within the cyclone chamber. To helpincrease the air flow velocity the cross-sectional area of the flowchamber, in the flow direction, may be varied, and preferably isreduced. Accelerating the dirty air to a relatively higher velocity mayhelp disentrain fine dirt particles.

The air outlet of the fine particle separator flow chamber may beconfigured to disrupt the flow of air exiting the flow chamber.Disrupting the flow of air, for example by introducing eddy currentsand/or turbulence and/or directing the air away from the cyclone dirtoutlet, may help separate fine dirt particles from the air stream.Separated dirt particles may fall into the dirt collection chamber.

An advantage of this configuration may be a more efficient separation offine dirt particles from the dirty air stream. Separating fine dirtparticles from the dirty air stream in the fine particle separator mayhelp prevent the fine dirt particles from continuing downstream from thecyclone bin assembly, and, for example, fouling the suction motor and/ora pre-motor filter.

In accordance with this aspect, a surface cleaning apparatus comprisesan air flow passage extending from a dirty air inlet to a clean airoutlet. The air flow passage includes a suction motor. The surfacecleaning apparatus may comprise a cyclone chamber in the air flowpassage. The cyclone chamber may comprise a cyclone chamber first endand a cyclone chamber second opposed end, a cyclone air inlet, a cycloneair outlet and a cyclone chamber wall. The surface cleaning apparatusmay comprise a dirt collection chamber having a dirt collection chamberfirst end, a dirt collection chamber second opposed end and an outerlongitudinally extending sidewall. The outer longitudinally extendingsidewall may have at least one recess provided therein.

The recess may extend longitudinally.

The recess may extend essentially from the dirt collection chamber firstend to the dirt collection chamber second opposed end.

The recess may comprise an outwardly extending concave surface.

The dirt collection chamber may comprise at least two angularly spacedapart recesses.

The recess may have an upstream side and a downstream side. The upstreamside may extend sharply away from the outer longitudinally extendingsidewall.

The recess may have an upstream side and a downstream side. The upstreamside may meet the outer longitudinally extending sidewall at a sharpcorner.

The recess may have an upstream side and a downstream side. The upstreamside may extend away from the outer longitudinally extending sidewall atan angle.

The angle may be between about 30° and about 75°, or more.

The recess may have a depth between about 6 mm and about 15 mm, or more.

According to yet another broad aspect of the teachings described herein,a surface cleaning apparatus comprises a cyclone chamber at leastpartially located within a dirt collection chamber such that at least aportion of the sidewall of the cyclone chamber is spaced from thesidewall of the dirt collection chamber to define a space therebetweenin communication with the dirt outlet of the cyclone chamber.Preferably, the space is an annular region such that the sidewall of thedirt collection chamber extends all the way around the sidewall of thecyclone chamber. A support surface extends between the sidewall of thedirt collection chamber and the sidewall of the cyclone chamber. Thesupport surface is configured to direct dirt towards the dirt collectionarea of the dirt collection chamber.

The cyclone chamber may have a generally circular sidewall, and agenerally annular gap may be formed between the cyclone chamber sidewalland a surrounding dirt collection chamber sidewall. The supportingsurface may comprise at least one declined surface or ramp surfaceextending away from the cyclone chamber dirt outlet, to help preventdirt particles from being retained on the support surface.

An advantage of this configuration is that dirt particles may be morelikely to fall into a lower portion of the dirt collection chamber, andmay be less likely to be retained on the support surface. This may helpfacilitate emptying of the dirt collection chamber when a floor of thedirt collection chamber is opened.

Preferably, the dirt collection chamber has a dirt collection surfacethat is opposed to and faces the end of the cyclone chamber opposed tothe end of the cyclone chamber having the dirt outlet (e.g., the dirtcollection surface may be below the cyclone chamber). Accordingly, theannular region of the dirt collection chamber may function as a passagefrom the cyclone dirt outlet to the dirt collection surface. If dirtparticles collect on the support surface, then those particles may bere-entrained in air flowing in the annular region.

A further advantage of this configuration is that the amount of dirtparticles that collect on the support surface may be reduced and theamount of dirt particles re-entrained in the air stream returning to thecyclone chamber may be reduced, thereby increasing the separationefficiency of the cyclone chamber and dirt collection chamber.

In accordance with this broad aspect, a surface cleaning apparatuscomprises an air flow passage extending from a dirty air inlet to aclean air outlet. A suction motor may be provided in the air flowpassage. A cyclone chamber may be provided in the air flow passage. Thecyclone chamber may comprise a cyclone air inlet, a cyclone air outlet,a cyclone dirt outlet and a cyclone chamber wall. A dirt collectionchamber may comprise a first end, a spaced apart opposed second end, adirt inlet in communication with the cyclone dirt outlet, an annularportion that surrounds at least a portion of the cyclone chamber, aninner side adjacent the cyclone chamber, and an outer side spaced fromthe cyclone chamber and defined by a dirt collection chamber sidewall. Asupport surface may extend between the inner side and the outer side andmay be configured to direct dirt towards a dirt collection area of thedirt collection chamber.

The support surface may extending part way around the annular portionand may extend away from the dirt inlet.

The support surface may have first and second ends that are angularlyspaced apart around the cyclone chamber. The support surface may extendcontinuously away from the dirt inlet from the first end to the secondend.

The support surface may have first and second ends that are angularlyspaced apart around the cyclone chamber and a mid-section. The supportsurface may extend continuously away from the dirt inlet from themid-section to the first end and to the second end.

The support surface may be curved and may have first and second endsthat are angularly spaced apart around the cyclone chamber. The supportsurface may extend towards the dirt inlet from the first and second endsat an angle of up to 50° from a plane transverse to a longitudinal axisof the cyclone chamber.

The support surface may extend towards the dirt inlet from the first andsecond ends at an angle from to 15° to 35° from a plane transverse to alongitudinal axis of the cyclone chamber.

The dirt inlet may be provided at the first end and the support surfacemay be spaced from the dirt inlet towards the opposed second end.

The cyclone dirt outlet may be the dirt collection chamber dirt inlet.

The dirt collection chamber may comprise a dirt collection area that isprovided at the opposed second end.

The dirt inlet may be at an upper end of the dirt collection chamber andthe dirt collection area may be in a lower portion of the dirtcollection chamber.

The cyclone chamber and the dirt collection chamber may be provided in acyclone bin assembly that is removably mounted to the surface cleaningapparatus.

The cyclone chamber may have a cyclone chamber first end and an opposedcyclone chamber second end and the cyclone dirt outlet is providedadjacent the cyclone chamber first end and the cyclone air inlet isprovided at the opposed cyclone chamber second end.

The cyclone chamber air outlet may be provided at the opposed cyclonechamber second end.

The cyclone chamber first end may be an upper end of the cyclonechamber.

The cyclone chamber first end may be provided proximate the first end ofthe dirt collection chamber.

The cyclone chamber may have a cyclone chamber first end and an opposedcyclone chamber second end. The cyclone chamber may be providedproximate the first end of the dirt collection chamber. The opposedsecond end of the dirt collection chamber may be spaced from and mayface the opposed cyclone chamber second end.

Air may travel in the annular portion in a direction of rotation and thesupport surface may extend away from the dirt inlet in the direction ofrotation.

The support surface may have first and second ends that are angularlyspaced apart around the cyclone chamber. The support surface may extendcontinuously away from the dirt inlet from the first end to the secondend.

DRAWINGS

Reference is made in the detailed description to the accompanyingdrawings, in which:

FIG. 1 is a perspective view of an embodiment of a surface cleaningapparatus;

FIG. 2 is perspective cross sectional view of the cyclone bin assemblyof the surface cleaning apparatus of FIG. 1, taken along line 2-2 inFIG. 1;

FIG. 3 is a side view of the cyclone bin assembly as shown in FIG. 2;

FIG. 4 is a perspective cross sectional view of the cyclone bin assemblyas shown in FIG. 2, with its lid and dirt chamber floor open;

FIG. 5 is a perspective view of the cyclone bin assembly of from thesurface cleaning apparatus of FIG. 1, with its lid and dirt chamberfloor open;

FIG. 6 is a partial cut away view of the cyclone bin assembly of FIG. 5,with the lid and floor removed;

FIG. 7 a-7 e are alternate schematic representations of a fine particleseparator;

FIG. 8 is a side view of an alternate embodiment of a cyclone binassembly that is usable with a surface cleaning apparatus;

FIG. 9 is cross-sectional side view of the cyclone bin assembly of FIG.8;

FIG. 10 is a top perspective view of the cyclone bin assembly of FIG. 8,with the lid removed;

FIG. 11 is a bottom perspective view of the cyclone bin assembly of FIG.8, with the dirt chamber floor removed;

FIG. 12 a is a schematic side view of the cyclone bin assembly of FIG.2;

FIG. 12 b is a schematic side view of the cyclone bin assembly of FIG.8;

FIG. 12 c is a schematic side view of an alternate embodiment of acyclone bin assembly usable with a surface cleaning apparatus;

FIG. 12 d is a schematic side view of an alternate embodiment of acyclone bin assembly usable with a surface cleaning apparatus;

FIG. 13 is a perspective view of another example of a surface cleaningapparatus;

FIG. 14 is a perspective view of another cyclone bin assembly with thelid and floor removed;

FIG. 15 is a perspective sectional view taken along line 15-15 in FIG.14; and,

FIG. 16 is a partial cut away view of the cyclone bin assembly of FIG.14.

DETAILED DESCRIPTION

Referring to FIG. 1, an embodiment of a surface cleaning apparatus 100is shown. In the embodiment illustrated, the surface cleaning apparatus100 is an upright surface cleaning apparatus. In alternate embodiments,the surface cleaning apparatus may be another suitable type of surfacecleaning apparatus, including, for example, a hand vacuum, a canistervacuum cleaner, a stick vac, a wet-dry vacuum cleaner and a carpetextractor.

General Overview

As exemplified in FIG. 1, a surface cleaning apparatus 100 includes asurface cleaning head 102 and an upper section 104.

The surface cleaning head 102 may be any suitable type of cleaningapparatus, including, for example a powered cleaning head having arotating brush and a brushless cleaning head. The surface cleaning head102 may be of any suitable configuration and may include at least onewheel or other rolling support to contact the surface being cleaned.

In the illustrated example the surface cleaning head 102 includes a pairof rear wheels 106 and a pair of front wheels (optionally caster-typewheels, not shown) for rolling across a surface and a dirty air inlet108 provided at the front end.

If the surface cleaning apparatus is an upright surface cleaningapparatus, then the upper section 104 may be moveably connected to thesurface cleaning head 102 by any means known in the art. The uppersection 104 is moveable (e.g., pivotally mounted to the surface cleaninghead 102) between a storage position and an in use position. An air flowpassage extends from the dirty air inlet 108 to a clean air outlet 110,which is preferably provided on the upper section 104. The air flowpassage may include any suitable combination of rigid conduits, flexibleconduits, chambers and other features that may cooperate to direct aflow of air through the surface cleaning apparatus. The upper section104 may be of various configurations.

A handle 116 is preferably provided on the upper section 104 formanipulating the surface cleaning apparatus. The handle may be of anysuitable configuration that may be grasped by a user. While illustratedas being positioned toward the top of the upper section 104, the handle116 may be provided at any other suitable location on the surfacecleaning apparatus 100.

Referring to FIGS. 1 and 2, in the example illustrated, the uppersection 104 comprises an air treatment housing 112 and a suction motorhousing 114, which is preferably positioned below air treatment housing112. The air treatment housing 112 houses an air treatment member, whichis positioned in the air flow passage downstream from the dirty airinlet 108 to remove dirt particles and other debris from the air flowingthrough the air flow passage. The air treatment member 112 may be anysuitable type of treatment member that includes any one or more of thefeatures disclosed herein and may include, for example, a filter. In theillustrated example, the air treatment member comprises a cyclone binassembly 118 comprising a cyclone chamber 120 and a dirt collectionchamber 122. The suction motor housing 114 is configured to house asuction motor (not shown). Preferably, as exemplified, the suction motoris in air flow communication with the air flow passage, downstream fromthe cyclone bin assembly 118. The suction motor may be any suitablemotor and may be selected based on a plurality of factors including, forexample, suction strength, operating noise, power consumption andphysical size. The housing 114 may be formed to accommodate the selectedsuction motor as well as mating with and optionally supporting thecyclone bin assembly 118.

It will be appreciated that, depending upon the aspects that areincorporated into a surface cleaning apparatus, some of the exemplifiedfeatures may not be used or may be varied so as to be of any designknown in the art.

Cyclone Bin Assembly

Various different features for a cyclone bin assembly are disclosedherein. It will be appreciated that a cyclone bin assembly may use oneor more of these features. Accordingly, a cyclone bin assembly may useone or more a dirt collection chamber having a variable cross sectionalarea in a direction transverse to the longitudinal axis of the dirtcollection chamber, a fine particle separator, a rib provided in thedirt collection chamber, a reinforced floor construction for a dirtcollection chamber, recessed columns in the dirt collection chamber anda ramped or inclined surface in the dirt collection chamber. Aside fromcontaining one or more of these features, a cyclone bin assembly may beof any design.

For example, the cyclone bin assembly may be of any suitableconfiguration, size and shape. The cyclone chamber may be configured ina plurality of different configurations, including, for example, anupright cyclone, an inverted cyclone and a horizontal or transversecyclone. The dirt collection chamber may be configured to cooperate witha given cyclone chamber, as well as connecting with the rest of thesurface cleaning apparatus. The cyclone chamber may be integrally formedwith the dirt collection chamber, or optionally may be separable fromthe dirt collection chamber.

Preferably, at least a portion of the cyclone bin assembly is removablefrom the upper section of the surface cleaning apparatus to helpfacilitate emptying of the dirt collection chamber. To help facilitateemptying and/or inspection at least one of, or both of the top andbottom of the cyclone bin assembly may be openable to provide access tothe interiors of the cyclone chamber and/or the dirt collection chamber.

Optionally, some or all of the cyclone bin assembly 118 may be formedfrom a transparent or semi-transparent material, such as plastic, sothat a user may visually inspect the contents of the cyclone binassembly 118, for example the contents of the dirt collection chamber122, without having to open or disassemble the cyclone bin assembly 118.This may also allow a user to inspect the interior of the cyclone binassembly 118 while the surface cleaning apparatus 100 is in use.

As exemplified in FIGS. 2-6, the cyclone chamber 120 may be an invertedcyclone and may be oriented with the dirt inlet at an upper end thereof.In other configurations, it will be appreciated that cyclone chamber 120may be in a different orientation and may be of a differentconfiguration.

In the illustrated example the cyclone chamber 120 is bounded by asidewall 124, a first end wall 126 and a second end wall, or floor 128that are configured to provide an inverted cyclone configuration. A lid130 covers the top of the cyclone chamber 120, and an inner surface ofthe lid 130 comprises the first end wall 126 of the cyclone chamber 120.Preferably, the lid 130 is openable and/or detachable from the cyclonebin assembly 118 by any means known in the art.

Opening the lid 130 may allow a user to access the interior of thecyclone chamber 120, for example for cleaning. In the illustratedexample, the lid 130 is pivotally connected to the cyclone bin assembly118 by a hinge 132, and is movable between a closed configuration (FIG.2) and an open configuration (FIGS. 4 and 5). The lid 130 may be held inthe closed position by any means known in the art, such as a releasablelatch 134. A handle 136 may be provided on the lid 130. The handle 136may be used to manipulate the cyclone bin assembly 118 when it isdetached from the upper section 104.

Preferably, a tangential air inlet 138 is provided in the sidewall 124of the cyclone chamber 120 and is in fluid communication with the dirtyair inlet 108. The tangential air inlet 138 may be of any suitabledesign and/or cross sectional area and may be provided at any suitablelocation along the sidewall 124 of the cyclone chamber 120. Air flowinginto the cyclone chamber 120 via the air inlet 138 may circulate aroundthe interior of the cyclone chamber 120 and dirt particles and otherdebris may become disentrained from the circulating air.

A dirt collection chamber may be provided to receive and retain dirt anddebris that is separated from the dirty air flow via the cyclone chamber120. The dirt collection chamber may be any suitable configuration thatmay accommodate a given cyclone chamber, and may be formed from anysuitable material, including, for example plastic and metal. At least aportion of the air circulating within the cyclone chamber may flow intoand circulate within the dirt collection chamber when the cyclone binassembly is in use. After having circulated within the dirt collectionchamber, the air may flow back into the cyclone chamber and exit via theair outlet of the cyclone chamber.

Optionally, the dirt collection chamber may be a unitary, integrallyformed chamber.

The dirt collection chamber may be of any suitable cross-sectionalshape, and may have a varying cross-sectional shape along its height (asillustrated in FIG. 1 and discussed subsequently)

In the illustrated example, dirt collection chamber 122 is incommunication with cyclone chamber 120. Air with entrained dirt exitsthe cyclone chamber 120 via a cyclone dirt outlet 140 and enters thedirt collection chamber via a dirt collection chamber inlet. Aftercirculating in the dirt collection chamber 122, air may re-enter thecyclone chamber 118 via the dirt collection chamber inlet and thecyclone dirt outlet 140. Preferably, the dirt collection chamber inletand the cyclone dirt outlet 140 are the same element. For example, asexemplified, the cyclone dirt outlet 140 may be a slot formed betweenthe sidewall 124 and the first end wall 126. The slot 140 may alsofunction as a dirt inlet for the dirt collection chamber 122.

Debris separated from the air flow in the cyclone chamber 120 may travelfrom the cyclone chamber 120, through the dirt outlet 140 to the dirtcollection chamber 122. Preferably, the slot comprises a gap formedbetween the end of the sidewall 124 and end wall 126 that extends partway around the cyclone chamber 118 (e.g., up to 150°, preferably30-150°, more preferably)60-120°. Alternatively, the dirt outlet 140 maybe of any suitable configuration and may be provided at any suitableposition on the cyclone chamber 120.

As exemplified, the cyclone chamber 118 may be positioned within thedirt collection chamber 122 and the dirt collection chamber 122 maycomprise an annular portion surrounding part or the entire cyclonechamber 118. Alternately, or in addition, the cyclone chamber 118 may bepositioned such that a portion of the dirt collection chamber 122 ispositioned opposed to and facing (e.g., below) the air exit end of thecyclone chamber 118. The annular portion may merge into, and becontiguous with, the lower portion of the dirt collection chamber 122.

The cyclone chamber 120 extends along a longitudinal cyclone axis 156(FIG. 3). In the example illustrated, the longitudinal cyclone axis 156is aligned with the orientation of the vortex finder 144. The cyclonechamber 120 has a generally round cross-sectional shape and defines acyclone chamber diameter 158. Alternatively, the cyclone chamber 120 mayhave any suitable cross-sectional shape and configuration.

Optionally, at least a portion of the cyclone chamber, for example aportion of a sidewall or an end wall, may be integral with portion ofthe dirt collection chamber sidewall, lid, cover or other feature (forexample a fine particle separator as explained below). This may helpreduce the overall side of the cyclone bin assembly 118 and/or may helpfacilitate manufacturing of the cyclone bin assembly.

In the illustrated example, a rear a portion of the dirt collectionchamber sidewall 152 is integral with a rear portion of the cyclonechamber sidewall 124, and at least a portion of the second cyclone endwall 128 is integral with a portion of a first dirt collection chamberend wall 196.

Air Exit Duct—Reinforced Floor Construction for a Dirt CollectionChamber

In accordance with one aspect of this disclosure, which may be used byitself or with one or more other aspects set out herein, an end of adirt collection chamber, preferably the floor, has an air flow conduitextend therethrough and the floor is reinforced by one or more supportor stiffening members.

For example, air exiting the cyclone chamber may flow through an airoutlet through a portion of the dirt collection chamber. The air outletmay include any suitable type of conduit or air passage that is in airflow communication with the suction motor, including, for example, adown flow duct or other conduit.

Air travelling through the air exit conduit may be travelling at arelatively high speed and may be swirling or otherwise turbulent. Suchan air flow may tend to induce vibrations in the air exit conduit.Vibrations in the air exit conduit may tend to increase the noisegenerated by the cyclone bin assembly and/or may tend to damagecomponents of the surface cleaning apparatus and/or may tend to disturbdirt that has settled out in the dirt collection chamber therebyfacilitating the re-entrainment of such dirt.

In accordance with this aspect, the air exit conduit and/or the dirtcollection chamber may be configured to help reduce such air-inducedvibrations. For example, the air exit conduit may be buttressed by oneor more support or stiffening members.

In the illustrated example, air may exit the cyclone chamber 120 via anair outlet 142. As exemplified, the dirt collection chamber 122 ispreferably positioned below the lower end wall 128 of the cyclonechamber in which air outlet 142 (e.g., vortex finder 144) is provided.In this orientation, the lower end wall 128 functions as a dirtcollection surface. Preferably, the cyclone air outlet includes a vortexfinder 144 extending into the cyclone chamber 120 and a passage thatextends through a portion of the dirt collection chamber 122, andpreferably linearly through the dirt collection chamber, e.g. down duct146. Optionally, a screen 148 may be positioned over the vortex finder144. In some embodiments, the screen 148 and vortex finder 144 may beremovable. The down duct 146 may comprise a generally cylindrical ductmember extending through the interior of the dirt collection chamber122. Screen 148 may be any screen, shroud or the like known in the art.

In use, the down duct 146 and/or end wall 128 of the cyclone chamber 118may vibrate. The vibrations may produce an undesirable noise. Further,the vibrations may interfere with the dirt separation efficiency of thecyclone bin assembly. Vibrations induced by air flowing through downduct 146 may be transmitted to lower end wall 128 and may disturb dirtthat has settled thereon. Once spaced from lower end wall 128, thedisturbed dirt may then be re-entrained in air travelling in the dirtcollection chamber. Accordingly as exemplified, one or more stiffeningribs 150 may extend between the down duct 146 and the second end wall128. Providing stiffening ribs 150 may help reduce the vibration of thedown duct 146 and/or second end wall 128 when the surface cleaningapparatus 100 is in use. Alternatively, or in addition to connecting tothe second end wall 128, stiffening ribs 150 may be configured toconnect to the sidewall 152 and/or floor 154 of the dirt collectionchamber 122.

The stiffening ribs 150 may be of any suitable shape and size,including, for example, triangular and rectangular. The ribs 150 may beformed from any suitable material, including, for example metal andplastic. Optionally, the stiffening ribs 150 may be integrally formedwith the down duct 146 and/or portions of the cyclone chamber and/ordirt collection chamber. Alternatively, the ribs 150 may be separatemembers coupled to the down duct 146. The ribs 150 may optionally bedetachable or removable.

The stiffening ribs 150 may be sized to help stabilize the down duct 146while still allowing for a desired air flow circulation within the dirtcollection chamber.

Optionally, some of the stiffening ribs 150 may extend from the downduct 146 to the sidewall 152 of the dirt collection chamber. Others ofthe stiffening ribs 150 may extend from a fixed end adjacent the downduct 146 to a free end spaced apart from the down duct 146.

Optionally, the down duct 146 may be detachable from the second end wall128 of the cyclone chamber 120. If the down duct 146 is detachable fromthe second end wall 128, the stiffening ribs 150 may also be detachablefrom the down duct 146, or the second end wall 128 to help facilitateremoval of the down duct 146. Alternatively, the ribs 150 may remainattached to the cyclone bin assembly 118 (for example extending from thefloor of the cyclone chamber) when the down duct is removed from thecyclone bin assembly 118.

Preferably, at least one portion of the dirt collection chamber 122 isopenable and/or removable to help facilitate emptying of the dirtcollection chamber. In the illustrated example the floor 154 of the dirtcollection chamber 122 is openable. Opening the dirt collection chamberfloor 154 may help facilitate emptying dirt and other debris from thedirt collection chamber 122. In the example illustrated, the dirtcollection chamber floor 154 is pivotally connected to the dirtcollection chamber sidewall 152 by hinge 198, and is pivotable betweenand open position (FIGS. 3-5) and a closed position (FIG. 2). The dirtcollection floor 154 also comprises an air outlet aperture 200 thatallows air from the down duct 146 to pass through the floor 154, andinto the suction motor housing 114. Alternatively, any suitable type ofreleasable fastener may be used to secure the floor 154 to the sidewall152, including, for example, latches, pins, interference fit and clips.Optionally, sealing gaskets 202, or other sealing members, may beprovided around the perimeter of the floor 154 and around the air outletaperture 200, to help seal the dirt collection chamber 122 when thefloor 154 is closed.

Fine Particle Separator

In accordance with another aspect of this disclosure, which may be usedby itself or with one or more other aspects set out herein, a fineparticle separator is provided exterior to the cyclone chamber and incommunication with the cyclone chamber via the cyclone chamber dirtoutlet.

Circulating air at a first speed within the cyclone chamber 120 mayfacilitate separation of a first portion of the dirt and debris fromwithin the air flow. To help facilitate separation of a second, finerportion of the dirt and debris from the air flow it may be desirable tocirculate the air at a second speed. Preferably the second speed isfaster than the first speed, which may help disentrain finer dirtparticles from the air flow.

Optionally, the cyclone bin assembly may include a fine particleseparator. The fine particle separator may be positioned outside thecyclone chamber and optionally, may surround at least a portion of thecyclone chamber. Portions of the cyclone chamber sidewalls may beintegral with portions of the fine particle separator.

To help increase the velocity of the air flow, the fine particleseparator may have a smaller cross-sectional area than the cyclonechamber (in the direction of air flow). The cross-sectional area of thefine particle separator may be constant along its flow path, or may varyalong the flow direction. Preferably, the cross-sectional area of thefine particle separator (in the flow direction) may decrease in thedirection of the air flow, so that the area at an inlet of the fineparticle separator is greater than an area at an outlet of the fineparticle separator. This may help increase the velocity of the air flowas it travels through the fine particle separator.

As exemplified, the cyclone bin assembly 118 includes a fine particleseparator to help disentrain relatively fine dirt particles from thedirty air stream. In the example illustrated, the fine particleseparator comprises an air recirculation chamber 160 surrounding thecyclone chamber 120 wherein air may rotate or swirl prior to re-enteringthe cyclone chamber 118. Preferably, as exemplified, the airrecirculation chamber 160 comprises a generally annular flow chamber162, part or all of which may be between the cyclone chamber sidewall124 and an outer bin sidewall 164 (see for example FIG. 6). It will beappreciated that the annular flow chamber may be positioned above thecyclone chamber 118 and that some or all of the annular flow chamber 162may face the dirt outlet 140.

Optionally, the inner surface of the lid 130 may comprise an upper endwall 166 of the flow chamber 162. In this configuration, a user mayaccess the flow chamber 162 as well as the cyclone chamber 118 when thelid is opened, for example, for cleaning or inspection. Alternatively,the flow chamber 162 may have an upper end wall that is separate fromthe lid 130. Air circulating within the air recirculation chamber flowsin a rotational direction, generally about rotation axis 161.

Referring to FIG. 3, in the illustrated example, the flow chamber 162surrounds the cyclone chamber 120. Optionally, the height 170 of theflow chamber 162 may be selected so that it is approximately the sameheight 172 as the dirt outlet 140 of the cyclone chamber 120. In thisconfiguration, substantially all of the air exiting the cyclone chamber120 may flow into the air recirculation chamber 160. Alternatively, theflow chamber height 170 may be greater than or less than the dirt outletheight 172, and optionally may extend the entire height 174 of thecyclone chamber 120. This may adjust the amount of air exiting thecyclone chamber 120 that is drawn into the air recirculation chamber160. While illustrated in combination with a vertically oriented cyclonechamber 120, the air recirculation chamber 160 may also be used with acyclone chamber 120 oriented in another direction, including, forexample, a horizontal cyclone chamber.

The fine particle separator is preferably also in communication with thedirt collection chamber 122. Accordingly, dirt collection chamber 122may collect particulate matter separated by both the cyclone chamber andthe fine particle separator. Preferably, the end of the fine particleseparator closest to the dirt collection chamber 122 (e.g., the lowerend) is continuous with the dirt collection chamber 122. Alternatively,a separate dirt collection chamber may be provided to receive dirtseparated by the fine particle separator.

Referring to FIG. 6, when the surface cleaning apparatus is in use, atleast a portion of the dirty air circulating within the cyclone chamber120 may exit the cyclone chamber 118 via the dirt outlet 140 and travelinto the flow chamber 162, as illustrated using arrows 176. The airentering the flow chamber 162 may carry entrained dirt particles. Theair circulates in the annular flow chamber 162 before re-entering thecyclone chamber 118. Concurrently, particulate matter separated in thecyclone chamber 118 may be ejected through dirt outlet 140 and pass intothe dirt collection chamber 122.

Optionally, the cross sectional area of the annular flow chamber 162 ina plane transverse to the direction of rotation may be constant.Alternatively and preferably, as exemplified, the cross-sectional areaof the flow chamber varies, and preferably decreases, in the downstreamdirection. For example, the flow area of a first upstream portion 178 ofthe flow chamber 162 is greater than the flow area of a seconddownstream portion 180 of the flow chamber 162. In this configuration,when air flows from the first portion 178 into second portion 180, thevelocity of the air may increase. Preferably, the area may be selectedso that air traveling through the second portion 180 of the flow chamber162 is traveling at a higher velocity than the air circulating withinthe cyclone chamber 120. Circulating the air at an increased velocity inthe flow chamber 162 may help disentrain finer dirt particles then thosethat are disentrained in the cyclone chamber 118. Air exiting the secondportion 180 of the flow chamber passes through a second portion outlet182. Fine dirt particles disentrained in the air circulation chamber 160may fall into the dirt collection chamber 122.

As exemplified in FIGS. 5 and 6, the flow area of the second portion 180remains generally constant between the second portion inlet 184 and thesecond portion outlet 182. Alternatively, the second portion 180 may beconfigured so that the flow area of the second portion varies betweenthe inlet and outlet 184, 182. For example, the second portion 180 maybe configured so that the area at the outlet 182 is smaller than thearea at the inlet 184. This configuration may further increase thevelocity of the air traveling from the inlet to the outlet 184, 182.Alternatively, the second portion 180 may be configured so that the areaat the inlet 184 is less than the area at the outlet 182.

The cross-sectional area of the second portion 180 may be varied usingany suitable technique, including, for example, varying the spacingbetween the sidewalls of the second portion 180, varying the thicknessof one or more of the sidewalls and/or placing one or more inserts orother members within the flow area of the second portion 180. To varythe cross-sectional area in the second portion 180 in the illustratedexample, the thickness 186 of a portion of the cyclone chamber sidewall124 may be varied, or the thickness 188 of the outer bin sidewall 164may be varied, or both. Alternatively, instead of modifying the wallthicknesses 186, 188, a separate ramp insert may be positioned withinthe second portion 180 of the flow chamber. Alternately, or in addition,the height 170 of the annular flow region 162 may be varied.

Referring to FIG. 7 a, in a schematic representation of the secondportion 180 of the flow chamber 162, the thickness 186 of the cyclonechamber sidewall 124 at the inlet 184 is equal to the thickness 186 ofthe cyclone chamber sidewall 124 at the outlet 182. Similarly, thethickness 188 of the sidewall 164 at the inlet 184 is equal to thethickness 188 of the sidewall 164 at the outlet 182. While not shown,the height may remain constant such that the cross sectional arearemains constant.

In other embodiments, the wall thickness 186 at the outlet 182 may bedifferent than the wall thickness 186 at the inlet 184, as illustratedusing schematic representations in FIGS. 7 b-7 e. Similarly, the wallthickness 188 may be varied. FIGS. 7 e and 10 illustrate embodiments inwhich a separate ramp member 189 is placed within the second portion 180of the flow chamber 162, instead of varying the wall thickness 186 ofthe cyclone chamber sidewall 124.

Disrupting the air flow as it exits the second portion, for exampleusing an air contacting member, may help disentrain dirt particles. Itmay also be beneficial to temporarily divert the air flow exiting thesecond portion 180 away from the dirt inlet 140 to help disentrainfurther dirt particles which may help reduce the likelihood that dirtparticles will be carried within the air flow when it re-enters thecyclone chamber 120. Referring to FIGS. 5, 6 and 10, in the illustratedexample, a portion of the cyclone chamber sidewall 124 adjacent thesecond portion outlet 182 may be configured to disrupt the flow of airexiting the second portion outlet 182 and\or direct the air flow awayfor the dirt inlet 140. For example, the side wall or a ramp insert 189may be provided at the outlet 182 to that the distance between the airflow region of portion 180 at outlet 182 and outlet 140 is increased.This may cause the air to make a sharper turn to return to the cyclonechamber, which may assist in separating finer dirt particles from theair flow.

Alternately, or in addition, the cyclone chamber sidewall 124 maycomprise a relatively sharp corner 190, other any other suitablefeature, which may also help disrupt the air flow 176. Disrupting theair flowing past the corner 190 may help disentrain dirt particles fromthe air flow 176, and may help urge the air flow 176 a to re-enter thecyclone chamber 120 via the dirt outlet 140.

Optionally, the dirt outlet slot 140 may be configured to have a varyingslot height 172 along its length. Varying the height of the dirt outletslot 140 may alter the behaviour of the air flowing through the slot140, between the cyclone chamber 120 and the air recirculation chamber160, for example air flows 176 and 176 a. Alternatively, the dirt outletneed not be a single continuous slot, but can be any other suitableshape having one or more openings in the cyclone chamber sidewall.

Rib in the Dirt Collection Chamber

In accordance with another aspect of this disclosure, which may be usedby itself or with one or more other aspects set out herein, one or moreribs within the dirt collection chamber, and optionally extendingbetween the dirt collection chamber sidewall and the cyclone chambersidewall may be provided to help disentrain dirt from air circulatingwithin the dirt collection chamber.

The ribs are air contacting members and may be of any suitableconstruction so as to disrupt an air stream that may be travelling inthe dirt collection chamber. Accordingly, the ribs may be substantiallysolid and/or may contain one or more apertures or other openings throughwhich air may flow. The dirt collection chamber preferably comprises atleast an annular section and at least one rib, and preferably one rib,is positioned in the annular portion. The rib may extend along a portionof the length of the annular portion and preferably along all oressential al of the entire length.

The ribs may be formed from any suitable material and may be integrallyformed with the cyclone bin assembly or provided as separate members.The ribs may be any suitable shape, and may be positioned assubstantially vertical planar members, or positioned in any suitableorientation relative to the direction of air flow.

As exemplified in FIGS. 2-4, the dirt collection chamber comprises anannular portion and optionally, one or more ribs 194 may extend betweenthe cyclone chamber sidewall 124 and the dirt collection chambersidewall 152. The rib may be used with or without the fine particleseparator described previously.

Optionally, the ribs may extend only partway across the annular spacedbetween the sidewalls (having a free end spaced apart from one of thesidewalls 124, 152), but preferably extend completely across the annularspace between the dirt collection chamber and cyclone sidewalls 152,124. Preferably, the rib 194 is positioned generally adjacent orproximate the dirt outlet 140 and more preferably, is positioned on theside of the dirt outlet 140 towards end wall 154 of the dirt collectionchamber 122.

In this configuration, the rib is provided in the upper annular portionof the dirt collection chamber 122 and may be disposed below theoptional fine particle separator if one is used. The rib 194 mayaccordingly impede the flow of the air flow circulating within an upperportion of the dirt collection chamber 122, which may help separate dirtparticles from the air stream and may reduce re-entrainment of separatedparticulate matter. Dirt particles contacting the rib 194 may bedisentrained from the air flow and fall in the lower portion of the dirtcollection chamber 122.

Variable Dirt Collection Cross Sectional Area

In accordance with another aspect of this disclosure, which may be usedby itself or with one or more other aspects set out herein, thecross-sectional area of the dirt collection chamber may be varied alongits height to help alter the characteristics of the air circulatingwithin the dirt collection chamber.

It will be appreciated that the dirt collection chamber is positionedexterior to the cyclone chamber and may be of various designs. Asexemplified in FIG. 3, the dirt collection chamber 122 comprises anupper portion 204 and a lower portion 206. The upper portion 204 ispositioned adjacent the cyclone chamber 120 and comprises an upperportion sidewall 208 that at least partially surrounds the cyclonechamber 120. The upper portion 204 may also comprise some or all of theair recirculation chamber 160. In this configuration the upper portion204 of the dirt collection chamber 122 has a generally roundcross-sectional shape, and has an upper dirt chamber diameter 210.

As exemplified, the lower portion 206 of the dirt collection chamber ispositioned generally below the cyclone chamber 120. The lower portion206 has a lower portion sidewall 212 with a generally roundcross-sectional shape, and has a lower dirt chamber diameter 214. In theillustrated configuration, the lower dirt chamber diameter 214 isgreater than the upper dirt chamber diameter 210. In this configuration,the dirt collection chamber 122 may be described as having a stepped outconfiguration. A transition surface 216 may connect the upper and lowerportion sidewalls 208, 212. In the illustrated example, the transitionsurface 216 comprises an angled wall. In other examples, the transitionsurface may have another configuration, including, for example ahorizontal or curved wall.

When air flows across the transition surface 216 from one portion toanother (e.g. from the upper portion 204 to the lower portion 206 orfrom the lower portion 206 to the upper portion 204) the disruption inthe air flow induced by the flowing from one portion to another may helpdisentrain dirt particles from the air flow. The features of thetransition surface 216 and its intersection with sidewalls 208 and 212may be selected to help improve dirt separation.

The cross sectional area or diameter of the dirt collection chamber maybe varied using a plurality of other sidewall configurations. Forexample, referring to FIGS. 8-11, another embodiment of a cyclone binassembly 518 that may be used with a surface cleaning apparatus includesa cyclone chamber 520 and a dirt collection chamber 522. Features of thecyclone bin assembly 518 that are analogous to features of cyclone binassembly 118 are represented by like reference characters, indexed by400. Dirt collection chamber 522 includes an upper portion 604 and alower portion 606. In this embodiment, the upper dirt collectiondiameter 610 is greater than the lower dirt collection diameter 614. Inthis configuration, the dirt collection chamber 522 may be described ashaving a stepped in configuration.

By way of further example, referring to FIG. 12 a, a schematicrepresentation of the stepped out cyclone bin assembly 118 illustrates adirt collection chamber 122 with a lower portion diameter 214 that isgreater than the upper portion diameter 210. FIG. 12 b, is a schematicrepresentation of the stepped in cyclone bin assembly 518, in which theupper portion diameter 610 is greater than the lower portion diameter614. Other variable cross-section dirt collection chamber configurationsmay also be used. For example, FIG. 12 c is a schematic representationof another embodiment of a cyclone bin assembly 718. The dirt collectionchamber 722 in cyclone bin assembly 718 comprises an upper portion 804having an upper portion diameter 810, a lower portion 806 having a lowerportion diameter 812 and an intermediate portion 840 having anintermediate portion diameter 842. The upper and lower portion diameters810, 814 are generally equal, and are both greater than the intermediateportion diameter 842. In this configuration the dirt collection chamber822 comprises two transition surfaces 816. FIG. 12 d, is a schematicrepresentation of another embodiment of a cyclone bin assembly 918. Thedirt collection chamber 922 in cyclone bin assembly 918 comprises anupper portion 1004 having an upper portion diameter 1010, a lowerportion 1006 having a lower portion diameter 1014 and an intermediateportion 1040 having an intermediate portion diameter 1042. In thisexample, the upper and lower portion diameters 1010, 1014 are generallyequal, and are both less than the intermediate portion diameter 1042.Like dirt collection chamber 718, dirt collection chamber comprises twotransition surfaces 1016.

Changes in the cross-sectional area may be used to enhance theseparation efficiency of the cyclone chamber and associated dirtcollection chamber. By varying the transverse cross sectional area ofthe dirt collection chamber, the flow dynamics of the air in the dirtcollection chamber may be varied and the amount of dirt that isdisentrained from the air may be altered, or the amount of dirt that isre-entrained may be reduced. For example, if the cross sectional area ofthe portion of the dirt collection chamber distal to the dirt inlet(e.g., the lower portion 206) is less than the opposed portion (e.g. theupper portion with rib 194) adjacent the dirt inlet, then the air willslow down as it enters the upper portion. As the velocity decreases, theamount of dirt that may be re-entrained in the return airflow maydecrease. If the cross sectional area of the portion of the dirtcollection chamber distal to the dirt inlet (e.g., the lower portion) isgreater than the opposed portion (e.g. upper portion) adjacent the dirtinlet, then the air will slow down as it enters the lower portionallowing more dirt to be disentrained.

It will be appreciated that this aspect is preferably used with acyclone having an upper dirt outlet and/or a fine particle separatorand/or a dirt collection chamber having an annular portion.

Dirt Collection Chamber Wall Recesses

In accordance with another aspect of this disclosure, which may be usedby itself or with one or more other aspects set out herein, the sidewallof the dirt collection chamber may be configured to include one or morerecesses. These recesses, (which may be referred to as bump-outs) areconfigured to help cause eddy currents to disrupt the air that may becirculating in the dirt collection chamber and thereby assist indisentraining dirt projections and other structure features. Theserecesses may extend substantially the entire length of the dirtcollection chamber, or alternatively may be limited to select portionsof the dirt collection chamber. The features may be integrally formedwith the cyclone bin assembly, or provided as separate members.

Referring to FIGS. 5 and 6, in the illustrated example, the dirtcollection chamber sidewall 152 may comprise two recessed columns 220,on opposing sides of the dirt collection chamber 122. The recessedcolumns 220 may provide a discontinuity on the inner surface of theouter dirt collection chamber sidewall 152, which may create eddycurrents or other disruptions in the dirty air flow circulating withinthe dirt collection chamber 122, represented by arrows 176 b.Preferably, the angle 222 formed at the intersection between the dirtcollection chamber sidewall 152 and the upstream or leading edge 223 ofthe recessed column 220 walls is sufficient to create a relatively sharpcorner, which may help disrupt the air flow. Preferably, the angle 222is between about 30 and about 90°, and more preferably is between 45 and90°. Disrupting the circulation of the dirty air passing over therecessed columns 220 may help disentrain dirt particles. In otherembodiments, the dirt collection chamber 122 may comprise a differentnumber of recessed columns 220 and the columns 220 may be formed in anysuitable shape, including, for example square or rectangularcross-sectional shapes.

The depth 224 of the recessed columns 220 may be selected to provide asufficient depth such that an area with reduced or no air flow iscreated such that dirt particles may settle out and travel to the dirtcollection floor. Collecting dirt particles within the recessed columns220 may also help prevent re-entrainment of the dirt particles in thecirculating air flow. Preferably, the depth 224, represented using adashed line to approximate the circumference of the uninterruptedsidewall 152, is between about 6 and about 18 millimeters, or optionallymay be greater than 18 millimeters or less than 6 millimeters.

Connecting Wall

Referring to FIGS. 9 and 11, as an alternative to in addition to thestiffening ribs 550, the down duct 546 may include a generallyvertically oriented connecting wall 630 extending between the down duct546 and the dirt collection chamber sidewall 552. The connecting wallmay be used by itself or with any one or more other aspects of thisdisclosure. The connecting wall 630 may be of any suitable size andconfiguration, and may be positioned in any suitable orientation. Theconnecting wall 630 may extend along substantially the entire height ofthe down duct 546, or may be shorter than the down duct 546. Theconnecting wall 630 may be positioned in any suitable location along theheight of the down duct 546 and optionally may be configured to contactone or both of the cyclone chamber floor and the dirt collection chamberfloor, or may be spaced apart from both floors.

Preferably, as illustrated, the connecting wall 630 extends downwardfrom the upper end wall 596, and has a height 632 that is between about5% and about 80% of the height 634 of the lower portion 606 of the dirtcollection chamber 522. More preferably, the connecting wall height 632is between about 15% and 50% of the lower portion height 634. Theconnecting wall 630 may impede the circulation of the dirty air flowingwithin the lower portion 606. Impeding the circulation of the dirty airflow may help disentrain dirt particles from the dirty air flow. Thedisentrained particles may then be retained within the lower portion 606when the circulating air re-enters the cyclone chamber 520. Theconnecting wall 630 may also provide additional stiffness and vibrationdamping to the down duct 546, as described above.

Ramped or Inclined Surface in the Dirt Collection Chamber

In accordance with another aspect of this disclosure, which may be usedby itself or with one or more other aspects set out herein, a dirtcollection chamber may include a ramped or inclined surface in the dirtcollection chamber.

Dirt particles and other debris circulating within the dirt collectionchamber may tend to settle or be deposited on any horizontal surfaceswithin the dirt collection chamber. Dirt that is resting on horizontalsurfaces of the dirt collection chamber may become trapped or hung-upwithin the dirt collection chamber and may be difficult to empty fromthe chamber (for example by opening the floor of the chamber andallowing the dirt to fall our under the force of gravity). Accordingly,configuring such surfaces as inclined or ramped surfaces may help toreduce or minimize the surface area of any surfaces or other featuresthat may trap or retain dirt particles.

This aspect will be discussed with reference to FIG. 13-16 whichdisclose another example of a surface cleaning apparatus 2100. Surfacecleaning apparatus 2100 includes a surface cleaning head 2102 and anupper section 2104. The surface cleaning apparatus 2100 is generallysimilar to surface cleaning apparatus 100, and like features areidentified using like reference numerals indexed by 2000. It will beappreciated that the surface cleaning apparatus of FIGS. 13-16 is anexemplary embodiment and it may have any of the features discussed withrespect to the exemplary embodiment of FIGS. 1-12 and the surfacecleaning apparatus of FIGS. 1-12 may have any of the features discussedwith respect to the exemplary embodiment of FIGS. 13-16.

The surface cleaning head 2102 includes a pair of rear wheels 2106 and apair of front wheels (not shown) for rolling across a surface and adirty air inlet 2108. The upper section 2104 is moveably connected tothe surface cleaning head 2102. The upper section 2104 is moveable(e.g., pivotally mounted) between a storage position and an in useposition. An air flow passage extends from the dirty air inlet 2108 to aclean air outlet 2110 on the upper section 104. A handle 2116 isprovided on the upper section 2104 for manipulating the surface cleaningapparatus 2100.

As exemplified in FIGS. 13 and 14, the upper section 2104 comprises anair treatment housing 2112 and a suction motor housing 2114. The airtreatment housing 2112 houses an air treatment member comprising atleast one cyclone chamber and at least one dirt collection chamber,which is positioned in the air flow passage downstream from the dirtyair inlet 2108 to remove dirt particles and other debris from the airflowing through the air flow passage. In the illustrated example, theair treatment member comprises a cyclone bin assembly 2118 comprising acyclone chamber 2120 and a dirt collection chamber 2122. The suctionmotor housing 2114 is configured to house a suction motor (not shown).The suction motor is in air flow communication with the air flowpassage, preferably downstream from the cyclone bin assembly 2118.

In the illustrated example, the cyclone bin assembly 2118 is orientedvertically and the cyclone dirt outlet 2140 is provided at the upper endof the cyclone chamber 2120. It will be appreciated that the cyclone binassembly may be in other orientations when mounted to a surface cleaningapparatus and when in use.

The cyclone chamber 2120 is bounded by a sidewall 2126, a first (e.g.,upper) end wall 2126 and a second end wall 2128, (e.g., a floor).Preferably, as exemplified in FIGS. 14-16, the cyclone chamber 2120 isan inverted cyclone chamber. Accordingly, the dirt outlet 2140 isprovided above the cyclone air inlet

Preferably, as exemplified, the dirt outlet end of the cyclone chamber2120 is openable. Accordingly, a lid 2130 may cover the top of thecyclone chamber 2120, and an inner surface of the lid 2130 may comprisethe first end wall 2126 of the cyclone chamber 2120. Preferably, the lid2130 is openable. Opening the lid 2130 may allow a user to access theinterior of the cyclone chamber 2120, for example for cleaning. In theillustrated example, the lid 2130 is pivotally connected to the cyclonebin assembly 2118 by a hinge 2132, and is movable between a closedconfiguration and an open configuration. The lid 2130 may be held in theclosed position by any suitable mechanism, including, for example areleasable latch 2134. A handle 2136 is provided on the lid 2128. Thehandle 2136 may be used to manipulate the cyclone bin assembly 2118 whenit is detached from the upper section 2104. Other methods of moveablymounting or removably mounting the lid 2128 may be used.

Preferably, the cyclone air inlet comprises a tangential air inlet.Preferably, as exemplified, tangential air inlet 2138 is provided in thesidewall 2124 of the cyclone chamber 2120 and is in fluid communicationwith the dirty air inlet 2108. Air flowing into the cyclone chamber viathe air inlet may circulate around the interior of the cyclone chamber2120 and dirt particles and other debris may become disentrained fromthe circulating air.

Preferably, the dirt outlet 2140 comprises a gap provided between thesidewall 2124 of the cyclone chamber and first (upper) end wall 2126.The gap may extend part way or all the way around sidewall 2124.Preferably, as exemplified, the dirt outlet comprises a slot thatextends part way around sidewall 122 between the end of sidewall 124facing first end wall 2126 and first end wall 2126. Debris separatedfrom the air flow in the cyclone chamber 2120 may travel from thecyclone chamber 2120, through the dirt outlet 2140 to the dirtcollection chamber 2122.

Air may exit the cyclone chamber via an air outlet 2142. In theexemplified embodiment, the cyclone chamber 2120 is inverted and thedirt collection chamber includes a portion spaced from and facing theair outlet end of the cyclone chamber. Accordingly, the air exit conduitextends at least part way through the dirt collection chamber. Forexample, reference may be made to FIG. 14 and FIG. 16 in which the lowerportion 2168 of the dirt collection chamber 2122 positioned beneath thecyclone chamber 2120 has been removed. In this example, the cyclone airoutlet includes a vortex finder 2144 extending into the cyclone chamber2120. Optionally, a screen may be positioned over the vortex finder.Optionally, the screen and vortex finder 2144 may be removable.

A down duct 2144 extends from the vortex finder linearly through thelower portion 2168 of the dirt collection chamber 122. The down duct2146 comprises a generally cylindrical duct member and may extend in anydirection through the interior of the dirt collection chamber 2122.Optionally, the down duct 2146 may be detachable from the second endwall 2128.

The cyclone chamber 120 extends along a longitudinal cyclone axis 2156.In the example illustrated, the longitudinal cyclone axis 2156 isaligned with the orientation of the vortex finder 2144.

The dirt collection chamber 2122 comprises a sidewall 2152, a first(upper) end wall 150 and an opposing second end wall, or floor 2154. Thefirst end walls of the cyclone chamber and the dirt collection chambermay be configured to be openable concurrently, e.g., they may beintegrally formed. Alternately, or in addition, the second end walls ofthe cyclone chamber and the dirt collection chamber may be configured tobe openable concurrently, e.g., they may be integrally formed with eachother.

Referring to FIG. 13, the floor 2154 of the dirt collection chamber 2122is openable. Opening the dirt collection chamber floor 2154 may helpfacilitate emptying dirt and other debris from the dirt collectionchamber 2122. In the example illustrated, the dirt collection chamberfloor 2154 is pivotally connected to the dirt collection chambersidewall 2152 by a hinge, and is pivotable between and open position anda closed position. The dirt collection floor 2154 also comprises an airoutlet aperture that allows air from the down duct to pass through thefloor 2154. Optionally, sealing gaskets, or other sealing members, maybe provided around the perimeter of the floor 2154 and around the airoutlet aperture, to help seal the dirt collection chamber 2122 when thefloor 2154 is closed.

As exemplified, the dirt collection chamber 2122 has a portion adjacentthe cyclone dirt outlet 2140 that is preferably annular in shape (e.g.,the upper annular portion) and a second spaced apart portion extendingacross the outer surface of the air exit end of the cyclone chamber(lower portion 2168). Preferably, the portions are contiguous.

The dirt collection chamber 2122 has a dirt collection chamber dirtinlet 2153 that is in communication with the cyclone dirt outlet 2140.Preferably, the dirt inlet 2153 is the dirt outlet 2240 of the cyclonechamber 2120.

In the illustrated example, the cyclone chamber 2120 is nested towardsthe rear of the dirt collection chamber 2122 (relative to the directionof travel of the surface cleaning apparatus 2100), and a generallyannular space 2250 is defined between the cyclone chamber sidewall 2124and the dirt collection chamber sidewall 2152. The annular space 2250may have a constant width or the width may vary. Further, the annularspace may surround the entire height of the cyclone chamber 2120 or anypart or portion thereof. In other configurations, the space 2250 mayhave any other suitable shape and need not be curved or annular.

A support member, for example a support surface, may be provided to helpsupport the cyclone chamber 2120 within the cyclone bin assembly. Thesupport member may be any suitable combination of structural membersthat are configured to help connect the cyclone chamber to the dirtcollection chamber, and hold the relative spacing between these chamberswhile the surface cleaning apparatus is in use.

In the illustrated example, the support surface comprises a connectingwall 2252 that is provided in the annular space 2250 between the cyclonechamber sidewall 2124 and the dirt collection chamber sidewall 2152,rearward of the cyclone chamber 2120. Connecting wall 2252 surrounds aportion of the cyclone chamber 2120, and in the illustrated examplesurrounds approximately 50% of the cyclone chamber 2120. In otherexamples the connecting wall 2252 may surround more than or less than50% of the cyclone chamber 2120.

When the surface cleaning apparatus is in use, a portion of the dirtyair in the cyclone chamber 2120 may flow out of the dirt outlet 2140 andcirculate within the dirt collection chamber 2122 in a rotationdirection, as illustrated using arrows 2254. A portion of this air mayflow through the annular space 2250 behind the cyclone chamber 2120.Dirt particles entrained with the air circulating through annular space2250 may become disentrained from the air flow and may settle on theupper surface 2256 of the connecting wall 2252.

In accordance with this aspect of the disclosure, the connecting wall2252 is preferably configured to help shed the dirt particles thatsettle on the connecting wall 2252, and to urge the dirt particlestoward the lower portion 2168 of the dirt collection chamber 2122.Guiding the dirt particles toward the lower portion 2168 of the dirtcollection chamber 2122 may help facilitate the collection of dirt anddebris in the lower portion 2168 of the dirt collection chamber 2122,which may help facilitate emptying of the dirt collection chamber 2122.It may also help prevent dirt particles from being retained on the uppersurface 2256 of the connecting wall 2252. Preferably, the connectingwall 2252 does not comprise horizontal surfaces that may retain dirtparticles when the surface cleaning apparatus 2100 is in an uprightposition (for example see FIG. 13).

The connecting wall 2252 may be of any suitable shape and configuration,and may include any suitable combination of features to help inhibit theaccumulation of dirt and debris on the connecting wall 2252. In theillustrated example, the connecting wall 2252 has a high point 2260adjacent the tangential air inlet 2138 that is at a higher elevationthan the first and second ends 2262, 2264, thereby forming first andsecond ramp surfaces 2266, 2268. In this configuration, the high point2260 of the connecting wall is intermediate the first and second ends2262 and 2264, and is offset relative to a lateral centre line 2270cyclone chamber. Alternatively, the high point 2260 of the connectingwall 2252 may be aligned with the centre line 2270.

First and second ramp surfaces 2266, 2268 slope generally downwardlyfrom the high point 2260 toward the first and second ends 2262, 2264,respectively. In this configuration, the first and second ends 2262,2264 are positioned at the points of lowest elevation on the connectingwall 2252. Providing inclined ramp surfaces 2266, 2268 may help urgedirt particles settling on the ramp surfaces 2266, 2268 to move towardthe corresponding ends 2262, 2264 of the connecting wall 2252, and fallinto lower portion of the dirt collection chamber 2122. The slope of theramp surfaces 2266 and 2268 may be constant along their lengths, or mayvary.

The first ramp surface 2266 is preferably a generally smooth surfaceextending from the high point 2260 to the first end 2262. The secondramp surface 2268 may comprise a portion of the tangential air inletsidewall 2272 and comprises a kinked region 2274 where the air inletsidewall 2272 joins with the connecting wall 2252. Providing a kinkedregion 2274, or other type of discontinuity in the ramp surface 2268,may introduce eddy currents or other flow disturbances in the dirty airflow circulating within the annular space 2250. Introducing disturbancesin the air flow may help disentrain dirt particles from the air flow.Other surface features may also be provided on the ramp surfaces 2266and 2268.

Optionally, instead of positioning the high point 2260 of the connectionwall intermediate the first and second ends 2262 and 2264, the highpoint 2260 may be positioned at one of the ends 2262, 2264 of theconnecting wall 2252. For example, the connecting wall 2252 may beconfigured so that the first end 2262 is the point of highest elevation2260 and the second end 2264 is the point of lowest elevation, so thatthe connecting wall 2252 may slope generally downward from the first end2262 to the second end 2264, or vice versa. Preferably, at least one ofthe ends 2262, 2264 of the connecting wall is positioned at the point oflowest elevation of the connecting wall 2252. Positioning at least oneof the ends 2262, 2264 at the point of lowest elevation may help preventlow points or recesses along the length of the connecting wall 2252,which may trap dirt particles, from being formed between the high point2260 and the ends 2262, 2264 of the connecting wall.

The ramp surface may be sloped or declined at an angle between about 5degrees to about 80° relative to a plane that is perpendicular to thecyclone axis 2156 (for example a horizontal plane), preferably betweenabout 5° and about 50° and more preferably between about 15° and about35°. The slope of the ramped surfaces 2266, 2268 is preferably generallyconstant along their length. However, the slope of the ramped surfaces2266, 2268 may vary along the lengths of the surfaces 2266, 2268, sothat a given ramped surface 2266 or 2268 may comprise relatively steeperand relatively flatter portions.

In the example illustrated, a portion of the connecting wall 2252 isintegral with the tangential air inlet sidewall 2272. Accordingly, itwill be appreciated that the connecting wall may form, e.g., an uppersurface of the cyclone air inlet. Alternatively, the tangential airinlet sidewall 2272 may be separate from the connecting wall 2252 and/ormay not pass through the dirt collection chamber 2120.

It will be appreciated that the following claims are not limited to anyspecific embodiment disclosed herein. Further, it will be appreciatedthat any one or more of the features disclosed herein may be used in anyparticular combination or sub-combination, including, withoutlimitation, a dirt collection chamber with a variable diameter or crosssectional area, the fine particle separator, an annular dirt collectionchamber with a rib or baffle, reinforcing ribs for a cyclone chamberfloor, a down flow duct and a recess in the outer sidewall of the dirtcollection chamber and/or a connecting wall.

What has been described above has been intended to be illustrative ofthe invention and non-limiting and it will be understood by personsskilled in the art that other variants and modifications may be madewithout departing from the scope of the invention as defined in theclaims appended hereto.

The invention claimed is:
 1. A surface cleaning apparatus comprising:(a) an air flow passage extending from a dirty air inlet to a clean airoutlet and including a suction motor; (b) a cyclone bin assemblypositioned in the air flow passage and comprising a cyclone chambercomprising a cyclone air inlet, a cyclone air outlet and a dirt outlet,and a dirt collection chamber having a radial outer wall, the cyclonebin assembly having a bin first end, an opposed bin second end axiallyspaced apart from the bin first end in an axial direction, the radialouter wall comprising a first sidewall portion extending at least nearlyparallel to the axial direction, a second sidewall portion extending atleast nearly parallel to the axial direction, the first sidewall portionhaving a first width in a lateral direction generally orthogonal to theaxial direction, the second sidewall portion having a second width inthe lateral direction that is different to the first width and a firstinclined transition portion connecting the first sidewall portion andthe second sidewall portion and widening from the first width to thesecond width, wherein the first inclined transition portion is locatedat the cyclone air inlet.
 2. The surface cleaning apparatus of claim 1,wherein the first width is narrower than the second width.
 3. Thesurface cleaning apparatus of claim 1, wherein the radial outer wallfurther comprises a third sidewall portion extending at least nearlyparallel to the axial direction disposed axially from the first sidewallportion and the second sidewall portion, the third sidewall portionhaving a third width in the lateral direction and a second inclinedtransition portion connecting the third sidewall portion and one of thefirst and second sidewall portions.
 4. The surface cleaning apparatus ofclaim 1, wherein the cyclone bin assembly is removably mounted to thesurface cleaning apparatus.
 5. The surface cleaning apparatus of claim1, wherein the dirt collection chamber is positioned at the bin secondend and the bin second end comprises a pivotally openable door foremptying the dirt collection bin.
 6. The surface cleaning apparatus ofclaim 1, wherein the radical outer wall forms an exterior surface of thesurface cleaning apparatus.
 7. The surface cleaning apparatus of claim 1wherein the dirt outlet is located at an axial location along the firstsidewall portion.
 8. The surface cleaning apparatus of claim 7 whereinthe cyclone chamber comprises a cyclone chamber first end, an opposedcyclone chamber second end axially spaced apart from the cyclone chamberfirst end in the axial direction and the cyclone chamber second end ispositioned between the cyclone chamber first end and the second end ofthe dirt collection chamber, whereby the second end of the dirtcollection chamber is opposed to and faces the cyclone chamber secondend to define a dirt collection area between the second end of the dirtcollection chamber and the cyclone chamber second end.
 9. The surfacecleaning apparatus of claim 8 wherein the second sidewall portion islocated along the dirt collection area.
 10. A surface cleaning apparatuscomprising: a) an air flow passage extending from a dirty air inlet to aclean air outlet and including a suction motor; b) a cyclone chamberdisposed within the air flow path and comprising a cyclone air inlet, acyclone air outlet and a dirt outlet; c) a dirt collection chamberexternal the cyclone chamber and in communication with the cyclonechamber dirt outlet, a dirt collection chamber first end, an opposeddirt collection chamber second end spaced apart from the dirt collectionchamber first end along a chamber axis and a sidewall extending betweenthe dirt collection chamber first and second ends, the sidewallcomprising a first sidewall portion extending at least nearly parallelto the chamber axis toward the dirt collection chamber first end andhaving a first width in a lateral direction that is generally orthogonalto the chamber axis, a second sidewall portion extending at least nearlyparallel to the chamber axis and disposed between the first sidewallportion and the dirt collection chamber second end and having a secondwidth in the lateral direction that is different than the first width,and an inclined transition sidewall portion extending from the firstsidewall portion to the second sidewall portion and connecting the firstsidewall portion and the second sidewall portion wherein the cyclone airoutlet is positioned adjacent the inclined transition sidewall portionin an outer wall of the cyclone chamber.
 11. The surface cleaningapparatus of claim 10, wherein the second sidewall portion extendscontinuously from the transition sidewall portion to the dirt collectionchamber second end.
 12. The surface cleaning apparatus of claim 10,wherein the second dirt collection chamber end comprises a laterallyextending end wall that is openable to empty the dirt collectionchamber.
 13. The surface cleaning apparatus of claim 10, wherein thedirt outlet is positioned adjacent the dirt collection chamber first endand is located at an axial location along the first sidewall portion.14. The surface cleaning apparatus of claim 13, wherein the cyclonechamber comprises a cyclone chamber first end and an opposed cyclonechamber second end axially spaced apart from the cyclone chamber firstend and the cyclone air inlet is at the second end of the cyclonechamber, the dirt outlet is provided at the first opposed end of thecyclone chamber and the cyclone chamber second end is positioned betweenthe cyclone chamber first end and the second end of the dirt collectionchamber.
 15. The surface cleaning apparatus of claim 14, wherein thedirt outlet is at an upper end of the cyclone chamber.
 16. The surfacecleaning apparatus of claim 10, wherein the dirt collection chamber atleast partially laterally surrounds the cyclone chamber and the cycloneair inlet passes through the dirt collection chamber sidewall.
 17. Thesurface cleaning apparatus of claim 13 wherein the cyclone chamber islaterally surrounded by the first sidewall portion of the dirtcollection chamber.
 18. The surface cleaning apparatus of claim 10,wherein the dirt collection chamber first end is an upper end, the dirtinlet is provided at the upper end, and a dirt collection area isprovided in a lower portion of the dirt collection chamber.
 19. Thesurface cleaning apparatus of claim 10, wherein the cyclone chamber andthe dirt collection chamber are provided in a cyclone bin assembly andthe cyclone bin assembly is removably mounted to the surface cleaningapparatus.
 20. The surface cleaning apparatus of claim 10 wherein theinclined transition sidewall portion extends outwardly in the lateraldirection from the first width to the second width.
 21. A surfacecleaning apparatus comprising: a) an air flow passage extending from adirty air inlet to a clean air outlet and including a suction motor; b)a cyclone chamber disposed within the air flow path and comprising acyclone air inlet, a cyclone air outlet, a dirt outlet, a cyclonechamber first end, an opposed cyclone chamber second end axially spacedapart from the cyclone chamber first end in an axial direction and acyclone chamber sidewall extending therebetween; c) a dirt collectionchamber external to the cyclone chamber and in communication with thecyclone chamber dirt outlet, a dirt collection chamber first end, anopposed dirt collection chamber second end spaced apart from the dirtcollection first end along a chamber axis and a dirt collection chambersidewall extending between the dirt collection chamber first and secondends, the cyclone chamber second end being positioned between thecyclone chamber first end and the second end of the dirt collectionchamber, the dirt collection chamber sidewall comprising a firstsidewall portion extending at least nearly parallel to the chamber axistoward the dirt collection chamber first end and having a first width ina lateral direction that is generally orthogonal to the chamber axis, asecond sidewall portion extending at least nearly parallel to thechamber axis and disposed between the first sidewall portion and thedirt collection chamber second end and having a second width in thelateral direction that is different than the first width, and aninclined transition sidewall portion extending from the first sidewallportion to the second sidewall portion and connecting the first sidewallportion and the second sidewall portion wherein the first width and thesecond width are wider than a maximum width of the cyclone chambersidewall.
 22. The surface cleaning apparatus of claim 21 wherein thedirt outlet is located at an axial location along the first sidewallportion.
 23. The surface cleaning apparatus of claim 22 wherein thesecond end of the dirt collection chamber is opposed to and faces thecyclone chamber second end to define a dirt collection area between thesecond end of the dirt collection chamber and the cyclone chamber secondend.
 24. The surface cleaning apparatus of claim 23 wherein the secondsidewall portion is located along the dirt collection area.
 25. Thesurface cleaning apparatus of claim 24 wherein the inclined transitionsidewall portion extends outwardly in the lateral direction from thefirst width to the second width.
 26. The surface cleaning apparatus ofclaim 24 wherein the cyclone air outlet is positioned proximate theinclined transition sidewall.
 27. The surface cleaning apparatus ofclaim 24 wherein the cyclone air inlet is positioned proximate theinclined transition sidewall.